Manufacturing method for electrical connector

Abstract

To provide a method of manufacturing an electrical connector, capable of achieving an improvement in joining strength while the size may be reduced.SOLUTION: In a method of manufacturing an electrical connector, sufficient joining strength may be easily obtained by applying ultrasonic vibration to a contact 12 and a center conductor SCa of a coaxial cable SC while the contact is brought into contact with the center conductor.SELECTED DRAWING: Figure 17

Description

[Technical field]

[0001] The present invention relates to electric The present invention relates to a method for manufacturing an electrical connector. [Background technology]

[0002] In general, in various electronic devices or electrical devices such as smartphones and tablet computers, it is common to connect a coaxial cable for signal transmission to a wiring board via an electrical connector. In such electrical connectors, the following patent document, for example, proposes applying ultrasonic vibrations when performing a process of connecting the central conductor of the coaxial cable to a conductive contact (terminal). In the manufacturing method disclosed in the patent document, first, the contact (terminal) is fixed to a housing, and then the central conductor of the coaxial cable is abutted against the contact (terminal), and then a jig such as a horn and anvil is inserted into the housing, and ultrasonic vibrations are applied in a state in which the central conductor of the coaxial cable and the contact (terminal) are sandwiched between the horn and the anvil. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2018-60727 A DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0004] However, when a jig such as a horn or anvil that applies ultrasonic vibration is inserted inside the housing as described above, the design of the housing is restricted by the need to consider the space for inserting the jig such as the horn or anvil, which reduces the freedom of design and may make it difficult to miniaturize the housing. In addition, the design of a jig such as a horn or anvil that applies ultrasonic vibration is also restricted by the structure of the housing, which may make it impossible to design the jig to obtain an optimal resonance point when applying ultrasonic vibration, and may make it impossible to obtain sufficient joint strength between the central conductor of the coaxial cable and the contact.

[0005] In particular, in recent years, there has been a demand for electrical connectors to be significantly smaller in size in addition to higher signal frequencies, and this has led to a tendency for the strength of the connection between the central conductor of the coaxial cable and the contacts to decrease, which has created a need for a structure that can connect the central conductor of the coaxial cable to the contacts with high strength to improve the stability of the electrical connection while still miniaturizing the electrical connector.

[0006] Therefore, the present invention is intended to increase the degree of freedom in designing the housing and jigs such as the horn and anvil, thereby enabling miniaturization while improving the joining strength. The phone To provide a method for manufacturing an electrical connector of The purpose is. [Means for solving the problem]

[0007] above DetailsIn order to achieve this object, in the invention of claim 1, in a manufacturing method of an electrical connector in which a contact for signal transmission made of a conductive material is attached to a housing made of an insulating material while a central conductor of a coaxial cable is connected to the contact, a joining process using ultrasonic vibration is performed to form a contact assembly in which the central conductor of the coaxial cable is joined to the contact by applying ultrasonic vibration to the contact before attachment to the housing, and then an assembly process is performed to attach the contact of the contact assembly formed in the joining process using ultrasonic vibration to the housing.

[0008] According to this manufacturing method for an electrical connector, the horn, anvil, and other tools that apply ultrasonic vibrations are used in a location independent of the housing, and are no longer inserted inside the housing as in the past, which reduces the constraints on designing the housing and increases the degree of freedom in design, making it easier to miniaturize the electrical connector, etc. Also, the horn, anvil, and other tools that apply ultrasonic vibrations are no longer restricted by the structure of the housing, making it possible to design them to obtain an optimal resonance point, and efficient ultrasonic vibrations can be applied, making it easy to obtain sufficient joint strength between the central conductor of the coaxial cable and the contact.

[0009] At this time, as in the invention according to claim 2, in the assembling step, the contacts of the contact assembly can be attached by being press-fitted into the housing.

[0010] Furthermore, as in the invention according to claim 3, in the assembling step, it is possible to mold the housing by insert molding after the contact assembly is set inside a mold.

[0011] According to this manufacturing method for an electrical connector, the connection portion between the contact and the central conductor of the coaxial cable is held by the housing, thereby stabilizing the electrical connection state of the electrical connector and improving its strength.

[0012] Furthermore, as in the invention of claim 4, in the joining process using ultrasonic vibration, the tip face of a horn is abutted against the central conductor of the coaxial cable, and an anvil is abutted against the contact, and ultrasonic vibration is applied while the contact and the central conductor of the coaxial cable are sandwiched between the horn and the anvil, and it is also possible to provide a recess in the tip face of the horn to accommodate the central conductor of the coaxial cable.

[0013] Furthermore, as in the invention of claim 5, it is desirable that the recess provided in the horn is a groove-like portion extending along the extension direction of the central conductor of the coaxial cable, the groove-like portion having a groove opening having a groove width corresponding to the central conductor of the coaxial cable, and a pair of groove side walls extending opposite each other from the groove opening toward a groove bottom that is the bottom of the groove-like portion, and the distance between the pair of groove side walls narrows from the groove opening toward the groove bottom.

[0014] According to the manufacturing method of the electrical connector having such a configuration, ultrasonic vibration is efficiently transmitted to the central conductor of the coaxial cable and the contacts via the groove side wall portion consisting of the inclined surface provided on the horn. 。 Effect of the Invention

[0015] As described above, the present invention can improve the joining strength while miniaturizing the electrical connector. [Brief description of the drawings]

[0016] [Figure 1]1 is an explanatory external perspective view, viewed from above and on the front side, of an electrical connector (plug connector) manufactured by applying a method according to an embodiment of the present invention and a coaxial cable connected thereto. FIG. [Diagram 2] FIG. 2 is an explanatory plan view of the electrical connector (plug connector) shown in FIG. [Diagram 3] FIG. 3 is an explanatory vertical cross-sectional view taken along line III-III in FIG. 2. [Figure 4] FIG. 4 is an external perspective view of the electrical connector (plug connector) shown in FIGS. 1 to 3 in an initial state before contacts are attached, as viewed from above and behind. [Diagram 5] FIG. 5 is an explanatory plan view of the electrical connector (plug connector) shown in FIG. [Figure 6] 1 is an explanatory external perspective view showing a state in which an end portion of a coaxial cable is arranged above an inner conductor contact (signal contact member) so as to face the upper side thereof, from the front. FIG. [Figure 7] 1 is an explanatory side view showing a state in which an inner conductor contact (signal contact member) is set on an anvil. FIG. [Figure 8] FIG. 8 is a rear explanatory view of the state shown in FIG. 7. [Figure 9] FIG. 1 is an explanatory side view showing the state before joining, in which an end portion of a central conductor (signal wire) of a coaxial cable is placed above an inner conductor contact (signal contact member) held on an anvil, and a horn is further placed above the central conductor (signal wire) of the coaxial cable so as to face it. [Figure 10] FIG. 10 is an explanatory cross-sectional view taken along line XX in FIG. [Figure 11] 1 is an explanatory side view showing the process of lowering a horn after an end portion of a central conductor (signal wire) of a coaxial cable is brought into contact from above with an inner conductor contact (signal contact member) held on an anvil. [Figure 12] FIG. 12 is an explanatory cross-sectional view taken along line XII-XII in FIG. [Figure 13]This is an explanatory side view showing the state in which the horn is lowered from the state shown in Figure 11 to press the tip surface (lower end surface) of the horn against the terminal portion of the central conductor (signal wire) of the coaxial cable and perform the joining process by applying ultrasonic vibration through the horn, with the horn reaching the lowered end. [Figure 14] FIG. 14 is an explanatory cross-sectional view taken along line XIV-XIV in FIG. 13. [Figure 15] FIG. 15 is an explanatory cross-sectional view in which the horn is raised from the state shown in FIG. 14. [Figure 16] 1 is an explanatory external perspective view showing a state in which a central conductor (signal wire) of a coaxial cable has been joined to a rear end portion of an inner conductor contact (signal contact member) from above on the front side. FIG. [Figure 17] FIG. 1 is an explanatory external perspective view showing a contact assembly in which a central conductor (signal wire) of a coaxial cable is joined to an inner conductor contact (signal contact member) and positioned above and facing an electrical connector (plug connector) in an initial state, viewed from above and behind. [Figure 18] FIG. 18 is an explanatory external perspective view showing, from above and behind, the state in which a contact assembly has been inserted into the contact accommodating space of an electrical connector (plug connector) in an initial state from the state shown in FIG. 17, and the inner conductor contact (signal contact member) has been attached to the housing by press-fitting. [Figure 19] 19 is an explanatory side view illustrating a state in which an inner conductor contact (signal contact member) of the contact assembly shown in FIG. 18 is attached to the electrical connector (plug connector). FIG. [Figure 20] 13 is an explanatory vertical cross-sectional view showing a state in which a coaxial cable is connected to an electric connector (plug connector) according to another embodiment of the present invention. FIG. [Figure 21] FIG. 13 is an explanatory external perspective view showing a terminal portion of a coaxial cable according to still another embodiment of the present invention from above and on the front side. [Figure 22] 22 is an explanatory front view of a horn disposed above and facing an end portion of a central conductor (signal line) of a coaxial cable according to the embodiment shown in FIG. 21. FIG. [Figure 23]FIG. 13 is an explanatory external perspective view showing a terminal portion of a coaxial cable according to still another embodiment of the present invention from above and on the front side. [Figure 24] 24 is an explanatory front view of a horn (or other molding die) disposed above and facing an end portion of a central conductor (signal line) of a coaxial cable according to the embodiment shown in FIG. 23. FIG. [Diagram 25] FIG. 13 is an explanatory external perspective view showing a terminal portion of a coaxial cable according to still another embodiment of the present invention from above and on the front side. [Figure 26] 26 is an explanatory front view of a horn (or other molding die) disposed above and facing an end portion of a central conductor (signal line) of a coaxial cable according to the embodiment shown in FIG. 25. FIG. [Figure 27] FIG. 13 is an explanatory external perspective view showing a terminal portion of a coaxial cable according to still another embodiment of the present invention from above and on the front side. [Figure 28] 28 is an explanatory front view of a horn (or other molding die) disposed above and facing an end portion of a central conductor (signal line) of a coaxial cable according to the embodiment shown in FIG. 27. FIG. [Figure 29] FIG. 30 is an explanatory external perspective view of a single inner conductor contact (signal contact member) to which the central conductor (signal line) of the coaxial cable according to the other embodiment of the present invention shown in FIGS. 21 to 29 is connected, as viewed from above on the front side. [Diagram 30] 30 is an explanatory external perspective view of the inner conductor contact (signal contact member) according to the other embodiment of the present invention shown in FIG. 29, viewed from above and behind. FIG. [Diagram 31] 31 is an explanatory external perspective view showing a state in which a central conductor (signal line) of a coaxial cable is joined to the inner conductor contact (signal contact member) shown in FIGS. 29 and 30, viewed from above and behind. FIG. [Diagram 32] 32 is an explanatory side view showing the electrical connector according to another embodiment of the present invention in a completed state with the shield shell in a closed state from the state shown in FIG. 31. FIG. [Diagram 33] FIG. 33 is an explanatory cross-sectional view taken along line XXXIII-XXXIII in FIG. 32. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment in which the present invention is applied to an electrical connector for a coaxial cable will be described in detail below with reference to the drawings.

[0018] [Overall structure of electrical connectors] First, the method shown in Figs. like, The present invention The method was applied to manufacture A terminal portion of a coaxial cable SC is connected to a plug connector 10 constituting the electrical connector according to the first embodiment, and the plug connector 10 to which the coaxial cable SC is connected is configured to be inserted from above into a mating electrical connector (not shown) such as a receptacle connector mounted on the main surface of a predetermined wiring board (not shown) and to be removed from the mated state. The operation of fitting and removing the plug connector 10 to and from the mating electrical connector (such as a receptacle connector) is performed in a direction substantially perpendicular to the main surface of the wiring board.

[0019] 1, the mating portion arranged in the front portion of the plug connector 10 is formed to have a substantially cylindrical shape, and the terminal portion of the coaxial cable SC is connected to the substantially cylindrical mating portion from one radially outward direction (rearward). Then, after the mating portion of the plug connector 10 is arranged facing the upper portion of the mated portion of the mating electrical connector (such as a receptacle connector), the entire plug connector 10 is lowered in a direction substantially perpendicular to the outer surface (main surface) of the printed wiring board, so that the lower end portion of the mating portion of the plug connector 10 is mated with the upper end portion of the mated portion of the mating electrical connector.

[0020] In this manner, when the plug connector 10 is inserted from above into the mating electrical connector (such as a receptacle connector) to be mated, the coaxial cable SC is connected to the conductive path of the wiring pattern on the wiring board via the plug connector 10 and the mating electrical connector (such as a receptacle connector), and signal transmission is performed.

[0021] Here, the direction in which the plug connector 10 is inserted into the mating electrical connector (such as a receptacle connector) is defined as the "downward direction" (negative direction of the Z axis in the figure), and the opposite direction in which it is removed is defined as the "upward direction" (positive direction of the Z axis in the figure). The coaxial cable SC extends from the "rear" of the plug connector 10 in a "horizontal direction" parallel to the surface of the wiring board, and the direction in which the coaxial cable SC extends from the plug connector 10 is defined as the "rearward direction" (negative direction of the Y axis in the figure), and the opposite direction is defined as the "forward direction" (positive direction of the Y axis in the figure). Furthermore, the direction perpendicular to both the "up-down direction" (positive and negative directions of the Z axis in the figure) and the "front-rear direction" (positive and negative directions of the Y axis in the figure) is defined as the "left-right direction" (positive and negative directions of the X axis in the figure).

[0022] [About coaxial cables] 6, the coaxial cable SC has a central conductor (signal line) SCa made of a conducting wire in the central portion of the coaxial cable SC, and an outer conductor (shield wire) SCb is coaxially laminated radially outward of the central conductor (signal line) SCa via a ring-shaped dielectric SCc. Furthermore, the outer surface of the outer conductor (shield wire) SCb is covered with an outer coating material SCd.

[0023] At the terminal portion of the coaxial cable SC having such a configuration, the outer coating material SCd is stripped off to expose the outer conductor (shield wire) SCb to the outside, and the outer conductor (shield wire) SCb and the dielectric SCc are further stripped off to expose the central conductor (signal wire) SCa to the outside. The terminal portion of the central conductor SCa arranged along the central axis of the coaxial cable SC is joined to an inner conductor contact (signal contact member) 12 attached to an insulating housing 11, and is electrically connected to form a signal circuit.

[0024] Here, the central conductor SCa of the coaxial cable SC in this embodiment is formed of a linear conductive member mainly composed of copper, and the outer surface of the central conductor SCa is plated with silver. As shown in Fig. 6 in particular, the end portion of the central conductor SCa plated with silver, i.e., the portion exposed to the outside by stripping, is joined to the inner conductor contact (signal contact member) 12 mounted in the insulating housing 11 by a manufacturing method described later, so that the cross section in the direction perpendicular to the extending direction of the central conductor SCa is made into a "polygonal shape". As a specific shape of the "polygonal shape" in this embodiment, a substantially triangular shape is adopted, and one side (lower side) of the three sides of the substantially triangular shape is joined to the flat surface closer to the "front" of the flat plate portion 12c of the inner conductor contact (signal contact member) 12 described above.

[0025] Furthermore, from both ends of one side of the "approximately triangular shape" that constitutes the cross-sectional shape at the terminal portion of the central conductor SCa of such a coaxial cable SC, more specifically, the side (lower side) that is joined to the inner conductor contact (signal contact member) 12, a pair of other sides extend diagonally upward, and the distance between these pair of other sides continuously decreases in the "upward direction", which is the direction away from the inner conductor contact (signal contact member) 12.

[0026] In this case, the cross section of the central conductor (signal line) SCa of the above-mentioned coaxial cable SC in a direction perpendicular to the extension direction (positive and negative directions of the Y axis in the figure) needs to be composed of a shape having at least three sides, and the side of the portion sandwiched between two of the three sides constituting the cross-sectional shape may be straight or curved, or may even be angular.

[0027] In this embodiment, the cross-sectional shape of the central conductor (signal line) SCa of the coaxial cable SC, more specifically, the cross-sectional shape in the direction perpendicular to the extending direction (positive and negative directions of the illustrated Y-axis) is "approximately triangular", and among the three flat surfaces having each of the three sides of the central conductor (signal line) SCa, the lower surface connected to the flat plate portion 12c of the inner conductor contact (signal contact member) 12 is made into a "first surface portion", as shown in Fig. 16 and Fig. 17. The "first surface portion" in this embodiment is composed of a single flat surface extending in the extending direction of the central conductor (signal line) SCa (positive and negative directions of the illustrated Y-axis), and the "second surface portion" arranged to face the "first surface portion" from above is composed of two flat surfaces extending in the extending direction of the central conductor (signal line) SCa (positive and negative directions of the illustrated Y-axis).

[0028] Each of the three flat surfaces constituting the "first surface" and the "second surface" has two edges, one edge and the other edge, extending in the extension direction of the coaxial cable SC (the positive and negative directions of the Y-axis shown in the figure), and one edge of each of the flat surfaces is directly connected to each other.

[0029] That is, initially, the central conductor SCa of the coaxial cable SC, which extends with a circular cross-sectional shape as shown in FIG. 6, is joined from above to an inner conductor contact (signal contact member) 12 attached to an insulating housing 11 as shown in FIG. 16 and FIG. 17, and as a result, a method using ultrasonic vibration is adopted to give the central conductor SCa of the coaxial cable SC an "approximately triangular" cross-sectional shape. The specific joining method and the method of attaching the inner conductor contact (signal contact member) 12 to the insulating housing 11 will be described in detail later as the gist of the present invention.

[0030] [About the insulating housing] The insulating housing 11 according to this embodiment is formed from a base frame-shaped member made of an insulating material, and the above-mentioned internal conductor contact (signal contact member) 12 and the shield shell 13 serving as a ground contact member are attached in an insulated state to the insulating housing 11. The structure for attaching these will be described later, but the insulating housing 11 according to this embodiment has a structure in which a tool such as a horn or anvil for applying ultrasonic vibration is not inserted inside, and therefore has a high degree of freedom in design.

[0031] 4 and 5, the insulating housing 11 has a substantially cylindrical fitting body 11a, and a connection support portion 11b protrudes substantially horizontally from a rear end portion (negative portion of the Y-axis) of the fitting body 11a toward the "rear" (negative direction of the Y-axis). In the fitting body 11a and the connection support portion 11b, a contact accommodating space 11c for accommodating the internal conductor contact (signal contact member) 12 is formed in a state that opens toward the "upward" (positive direction of the Z-axis).

[0032] More specifically, the fitting body 11a is formed of a hollow, generally cylindrical body, and a hollow portion formed through the radial center of the fitting body 11a constitutes a part of the contact receiving space 11c described above. The connection support 11b is formed in a gutter shape with a generally rectangular cross section that opens "upward" (positive direction of the Z axis in the figure), and the inner space of the connection support 11b constitutes the main part of the contact receiving space 11c described above. In this way, the contact receiving space 11c is composed of a space portion that communicates in a gutter shape from the connection support 11b to the fitting body 11a.

[0033] An internal conductor contact (signal contact member) 12 extending approximately horizontally is pressed into and attached to the bottom wall surface 11d of the inner wall surfaces of the wiring support portion 11b and the mating main body portion 11a, which form the contact accommodating space 11c.

[0034] [Signal contact materials] Here, as described above, the internal conductor contact (signal contact member) 12 which is attached to the insulating housing 11 by press-fitting functions as a connection terminal made of a conductive member, and is composed of a strip-shaped member having a flat portion 12c extending in an elongated shape along the "front-to-back direction" (positive and negative directions of the Y axis in the figure) as shown in Figure 6.

[0035] A pair of locking pieces 12a, 12a to be press-fitted into the insulating housing 11 are formed in the approximate center of the extending direction (front-rear direction represented by the positive and negative directions of the Y axis in the figure) of the flat plate portion 12c of the internal conductor contact (signal contact member) 12. These locking pieces 12a, 12a protrude outward in a plate shape from both end edges in the "left-right direction" (plate width direction represented by the positive and negative directions of the X axis in the figure) of the flat plate portion 12c, and the both locking pieces 12a, 12a are engaged so as to bite into the inner wall surface of the connection support portion 11b of the insulating housing 11 described above, thereby maintaining the entire internal conductor contact (signal contact member) 12 in a fixed state. (The state after fixing is shown in Figures 18 and 19.)

[0036] An end portion of the central conductor SCa of the coaxial cable SC described above is placed from "above" (positive direction of the Z axis) on a flat portion of the flat portion 12c of the inner conductor contact (signal contact member) 12, which is closer to the "rear" (negative direction of the Y axis in the figure), and joined by a method described below. Meanwhile, as shown in Fig. 6, a pair of elastic spring portions 12b, 12b extend integrally from both end edges in the plate width direction, which is the "left-right direction" (positive and negative directions of the X axis in the figure), toward the "downward" (negative direction of the Z axis in the figure) on a portion of the flat portion 12c of the inner conductor contact (signal contact member) 12 closer to the "front" (positive direction of the Y axis in the figure). As shown in Figure 3, which shows the completed state, both elastic spring portions 12b, 12b are inserted into a through hole provided in the mating main body portion 11a of the insulating housing 11, and inside the through hole in the mating main body portion 11a, both elastic spring portions 12b, 12b are arranged facing each other with a gap in between in the "left-right direction" (positive and negative directions of the X-axis in the figure).

[0037] When the lower portion of the mating main body portion 11a of the insulating housing 11 is inserted into the mating electrical connector (such as a receptacle connector), a signal conductive contact (not shown) having a pin shape or the like provided on the mating electrical connector (such as a receptacle connector) is inserted in contact with the portion between the two elastic spring portions 12b, 12b described above, thereby forming an electrically connected state, thereby forming a signal transmission circuit.

[0038] In this embodiment, the flat portion 12c extends in a flat state from the rear end portion where the pair of elastic spring portions 12b, 12b extend integrally to the front end portion (the end portion in the positive direction of the Y axis in the figure), but it is also possible to configure it to extend via a step from the elastic spring portions 12b, 12b.

[0039] [About Shield Shell] On the other hand, the outer peripheral portion of the insulating housing 11 is covered by a shield shell 13 made of a thin plate-like metal member, and the outer conductor SCb surrounding the central conductor SCa of the above-mentioned coaxial cable SC comes into contact with the shield shell 13 to establish an electrical connection, whereby the shield shell 13 functions as a conductive member for grounding, and a ground circuit is formed.

[0040] 4 and 5, the shield shell 13 made of a thin metal plate covering the outer surface of the insulating housing 11 is composed of an outer conductor shell 13a and a shell protrusion 13b that respectively partially cover the fitting main body 11a and the connection support portion 11b of the insulating housing 11. Of these, the outer conductor shell 13a constitutes a substantially hollow cylindrical ground contact member that mainly covers the fitting main body 11a of the insulating housing 11 in an annular shape from the outside in the radial direction.

[0041] That is, the outer conductor shell (ground contact member) 13a is disposed so as to surround the inner conductor contact (signal contact member) 12 from the outside, and the lower part of the outer conductor shell (ground contact member) 13a has a substantially cylindrical shape that is fitted onto the outer part in the radial direction of the mating electrical connector (receptacle connector, etc.).The fitting engagement part 13d consisting of an annular groove provided in the lower part of the outer conductor shell (ground contact member) 13a is configured to be electrically connected by being elastically fitted into a connecting lock part (not shown) provided in the mating electrical connector (receptacle connector, etc.).

[0042] Furthermore, a shell lid portion 13c that covers the fitting main body portion 11a and the connection support portion 11b of the insulating housing 11 from "above" (positive direction of the Z axis) is openably connected to an annular "upper" (positive direction of the Z axis) opening that constitutes the upper edge of the outer conductor shell 13a. That is, the shell lid portion 13c of the shield shell 13 is openably connected to the "front" (positive direction of the Y axis) edge portion of the outer conductor shell 13a via a connecting member 13c1 made of a thin plate-like member, and in the initial state before the coaxial cable SC is connected, it is in an open state standing "upper" (positive direction of the Z axis) as shown particularly in Figures 4 and 5.

[0043] 4 and 5, the inner conductor contact (a member constituting a contact assembly CA (see FIG. 16) described later in detail) after the central conductor SCa of the coaxial cable SC is joined is inserted from "above" (the positive direction of the Z axis in the figure) into the contact accommodating space 11c provided in the insulating housing 11 so as to be placed thereon, and the inner conductor contact (signal contact member) 12 is brought into an attached state by press-fitting. Thereafter, the above-mentioned connecting member 13c1 is bent at a substantially right angle, and the shell lid portion 13c of the shield shell 13 is pushed down to a substantially horizontal state, whereby the entire fitting body portion 11a and the connection support portion 11b of the insulating housing 11 are covered from above by the shell lid portion 13c, and the shield shell 13 is brought into a closed state (see FIGS. 1 to 3).

[0044] At this time, the shell lid portion 13c is configured to cover the opening portion "upper" (positive direction of the Z axis in the figure) of the outer conductor shell 13a when it is pushed down to a substantially horizontal position and closed as described above, and the portion of the shell lid portion 13c toward the "rear" (negative direction of the Y axis in the figure) of the shell lid portion 13c pushed down to the substantially horizontal position is configured as the rear cover portion 13c2, and the rear cover portion 13c2 is configured to cover the wiring support portion 11b of the insulating housing 11 and the shell protrusion portion 13b of the shield shell 13, as well as the outer conductor (shield wire) SCb of the coaxial cable SC from above.

[0045] As described above, the rear cover portion 13c2 constitutes the portion closer to the "rear" (negative direction of the Y-axis in the figure) of the shell lid portion 13c, and the first fixed retaining plate 13c3 and the second fixed retaining plate 13c4, which are made of a pair of tongue-shaped members, are provided on both side edges in the "left-right direction" (positive and negative directions of the X-axis in the figure) of the rear cover portion 13c2 so as to form flange plates. Among them, the first fixed retaining plate 13c3 is configured to be bent so as to cover the fixed shell portion 13b of the shield shell 13 from the outer side and to be fixed by crimping.

[0046] In other words, the two flange plates that constitute the pair of first fixed retaining plates 13c3, 13c3 are arranged so that when the shell lid portion 13c is pushed down to an approximately horizontal position, they are positioned outside the "left-right direction" (positive and negative directions of the X-axis in the figure) of the shell protrusion 13b of the shield shell 13, and from that state they are bent inwardly of the connector along both outer wall surfaces of the shell protrusion 13b as if being crimped, thereby fixing the shell lid portion 13c to the outer conductor shell 13a, and the shell protrusion 13b covering the outer surface of the wiring support portion 11b of the insulating housing 11 is fixed to the shell lid portion 13c in the "left-right direction" (positive and negative directions of the X-axis in the figure).

[0047] In addition, these first fixed retaining plates 13c3, 13c3 are provided with convex portions 13c5, 13c5 that protrude toward the inside of the connector in the "left-right direction" (positive and negative directions of the X-axis shown in the figure) (see Figure 4), and are formed so that when the first fixed retaining plates 13c3, 13c3 are bent toward the inside of the connector, the convex portions 13c5, 13c5 come into contact with a portion of the outer conductor (shielded wire) SCb of the coaxial cable SC.

[0048] The second fixed holding plate 13c4 is provided adjacent to and in parallel with the first fixed holding plate 13c3 at the "rear" (negative direction of the Y-axis in the figure) and is formed of a relatively small flange plate. The second fixed holding plate 13c4 is configured to be bent so as to cover the outer conductor (shield wire) SCb of the coaxial cable SC from the outside and fixed by crimping.

[0049] That is, both flange plates constituting the second fixed holding plate 13c4 are arranged so as to be located outside the outer conductor (shielded wire) SCb of the coaxial cable SC when the shell lid portion 13c is pushed down to a substantially horizontal position, and are bent inward from that position as if performing crimping. As a result, the shell lid portion 13c is fixed to the outer conductor (shielded wire) SCb of the coaxial cable SC, and the outer conductor SCb comes into contact with the second fixed holding plate 13c4, thereby forming a ground circuit by the shield shell 13.

[0050] In this embodiment, the outer conductor SCb is in contact with the second fixed holding plate 13c4, but a further fixed holding plate may be provided in front to fix the outer circumferential coating material SCd.

[0051] [Method of forming a contact assembly and method of assembling an inner conductor contact] Next, an embodiment relating to a method for forming a contact assembly by joining the center conductor (signal wire) SCa of a coaxial cable SC to the aforementioned inner conductor contact (signal contact member) 12 by ultrasonic vibration joining using an anvil and a horn, and a method for attaching the contact assembly formed by joining using ultrasonic vibration to an insulating housing 11 will be specifically described with reference to the drawings.

[0052] First, as shown in Figures 7 and 8, an internal conductor contact (signal contact member) 12 and an anvil TA, which serves as a receiving member for ultrasonic vibrations, are prepared, and the upper end surface of the anvil TA is abutted against the lower surface of the internal conductor contact (signal contact member) 12.

[0053] Next, as shown in Figures 9 and 10, the central conductor (signal line) SCa of the coaxial cable SC and the horn TH are prepared and arranged so as to face each other "above" (positive direction of the Z axis) of the anvil TA. Then, after making the terminal portion of the central conductor (signal line) SCa of the coaxial cable SC face the flat portion of the flat plate portion 12c of the single unit of the inner conductor contact (signal contact member) 12 "from above" (positive direction of the Z axis) (state of Figures 9 and 10), the central conductor (signal line) SCa of the coaxial cable SC is lowered in the negative direction of the Z axis, so that the terminal portion of the central conductor (signal line) SCa of the coaxial cable SC comes into contact with the flat portion of the inner conductor contact (signal contact member) 12 "from above" (positive direction of the Z axis).

[0054] Next, as shown in Figures 11 and 12, the tip surface (lower end surface) of the horn TH that applies ultrasonic vibration is lowered in the negative direction of the Z axis to abut against the end portion of the central conductor (signal line) SCa of the coaxial cable SC that is in contact with the "upper side" (positive direction of the Z axis) of the internal conductor contact (signal contact member) 12 from "above" (positive direction of the Z axis). In the state shown in Figures 11 and 12 in particular, the gap between the horn TH and the anvil TA facing each other vertically is set to a predetermined "α", and from the state with the gap α, the application of ultrasonic vibration accompanied by heating and pressurization is started by the horn TH, and the horn TH is gradually lowered to reach the state shown in Figures 13 and 14, that is, the state in which the gap between the horn TH and the anvil TA is changed to the predetermined "β".

[0055] In this way, the joining process using ultrasonic vibration is performed by applying the necessary ultrasonic vibration through the horn TH to the inner conductor contact (signal contact member) 12 and the central conductor (signal wire) SCa of the coaxial cable SC while they are sandwiched between the horn TH and the anvil TA. After performing such joining process, by raising the horn TH to its original position in the positive direction of the Z axis as shown in Figure 15, a contact assembly CA is formed in which the central conductor (signal wire) SCa of the coaxial cable SC is firmly joined to the inner conductor contact (signal contact member) 12 as shown in Figure 16.

[0056] At this time, a recess THa for accommodating the central conductor (signal line) SCa of the coaxial cable SC is provided on the tip surface (lower end surface) of the horn TH, which contacts the central conductor (signal line) SCa of the coaxial cable SC from "above" (positive direction of the Z axis in the figure). The recess THa provided on the tip surface (lower end surface) of the horn TH is formed of a groove-like portion extending along the extending direction (front-rear direction) of the central conductor (signal line) SCa of the coaxial cable SC. The groove-like portion forming the recess THa has a groove opening having a groove width corresponding to the outer diameter of the central conductor (signal line) SCa of the coaxial cable SC, on the tip surface (lower end surface) of the horn TH, and has groove side walls THb, THb consisting of a pair of tapered surfaces extending from the groove opening in a direction toward the bottom of the groove-like portion (upward in FIG. 10).

[0057] More specifically, the groove constituting the recess THa on the tip end surface (lower end surface) of the horn TH has a V-shaped cross section in a direction perpendicular to the extending direction of the central conductor (signal line) SCa of the coaxial cable SC. Specifically, the distance between groove side walls THb, THb consisting of a pair of tapered surfaces constituting the recess THa is set to a maximum groove width at the groove opening at the lower end, and is continuously reduced in the upward direction from the groove opening toward the bottom of the groove.

[0058] These groove side walls THb, THb are composed of two flat surfaces extending along the "front-rear direction" (positive and negative directions of the Y axis in the figure). Each of the two flat surfaces constituting each groove side wall THb has two edges consisting of one edge and the other edge extending in the extension direction (positive and negative directions of the Y axis), and one edge of each of the two edges is directly connected to each other.

[0059] In this way, by making the cross-sectional shape of the recess THa provided on the tip surface (lower end surface) of the horn TH V-shaped, ultrasonic vibrations are efficiently transmitted to the central conductor (signal line) SCa and inner conductor contact (signal contact member) 12 of the coaxial cable SC via the groove side wall portions THb, THb consisting of the tapered surface of the horn TH.

[0060] In this embodiment, in which the contact assembly CA is formed using the horn TH having the recess THa as described above, the end portion of the central conductor (signal line) SCa of the coaxial cable SC in the contact assembly CA is plastically deformed into a cross-sectional shape corresponding to the recess THa of the horn TH, so that the cross section in the direction perpendicular to the extending direction of the central conductor SCa has a polygonal (approximately triangular) shape (see Figs. 14 and 16). That is, a pair of other sides extending from both ends of one side (the side in contact with the inner conductor contact 12) of the central conductor (signal line) SCa are continuously narrowed in the direction away from the inner conductor contact 12.

[0061] In this case, if the terminal portion of the central conductor (signal line) SCa of the coaxial cable SC is a single wire, part of it will be plastically deformed and formed into a polygonal shape (approximately triangular), but if it is a twisted wire consisting of multiple wires, each wire will be plastically deformed as a whole and formed into a polygonal shape (approximately triangular).

[0062] In this embodiment, the cross-sectional shape of the groove-shaped portion at the tip surface of the horn TH is V-shaped, but the distance between the pair of groove side walls THb, THb may be a different shape as long as it narrows from the groove opening toward the groove bottom. For example, the groove side wall THb may be formed in a stepped shape. The groove bottom of the horn TH may be angular, curved, or linear. As a result, the end portion of the central conductor (signal line) SCa of the coaxial cable SC reflects the cross-sectional shape of the groove-shaped portion at the tip surface of the horn TH.

[0063] Next, the contact assembly CA formed by the above-mentioned ultrasonic vibration bonding process is taken out from the anvil TA, which is a receiving member for the ultrasonic vibration, and is attached to the insulating housing 11 in an assembly process. In this assembly process, as shown in Fig. 17, the contact assembly CA held by an appropriate means is first placed "above" (positive direction of the Z axis in the figure) the contact accommodating space 11c of the insulating housing 11 already assembled to the shield shell 13, and the inner conductor contact (signal contact member) 12 of the contact assembly CA is inserted toward the inside of the contact accommodating space 11c. As a result, as shown in Figs. 18 and 19 in particular, the contact assembly CA is attached, and the attachment of the contact assembly CA at this time is performed by pressing the locking portion 12a of the inner conductor contact (signal contact member) 12 constituting the contact assembly CA into the insulating housing 11.

[0064] According to such a manufacturing method for the plug connector 10, tools such as the horn TH and the anvil TA for applying ultrasonic vibrations are used in a location independent of the insulating housing 11, and are not inserted into the insulating housing 11 as in the past. Therefore, the constraints on designing the insulating housing 11 are reduced accordingly, and the design freedom is increased, which makes it easier to miniaturize the plug connector 10. In addition, the horn TH and the anvil TA, which are tools for applying ultrasonic vibrations, are no longer restricted by the structure of the insulating housing 11, so they can be designed to obtain an optimal resonance point, and sufficient joining strength can be easily obtained by applying efficient ultrasonic vibrations.

[0065] The semi-finished plug connector 10 (see Figures 18 and 19) obtained in the above manner is folded at approximately a right angle to close the shield shell 13, and the first fixed retaining plate 13c3 and the second fixed retaining plate 13c4 are further folded to cover them from the outside and crimped to complete the electrical connector 10.

[0066] In this embodiment, the terminal portion of the central conductor SCa of the coaxial cable SC is "silver plated" as described above, but the flat portion 12c of the inner conductor contact (signal contact member) 12, which is the counterpart of the joint, is "gold plated" at least at the portion where the central conductor SCa of the coaxial cable SC is joined. When joining is performed by ultrasonic vibration in this gold (Au)-silver (Ag) combination, as shown in Table 1 below, it has been found by experiments by the present inventors that a larger joint strength (Ave.) is obtained and the variation (σ) in the joint strength is also reduced compared to when joining is performed by ultrasonic vibration with other metal combinations (Au-Sn, Ni-Ag, Ni-Sn). [Table 1]

[0067] Next, the configuration of another embodiment shown in FIG. 20 will be described, in which the same members as those in the above-described embodiment are designated by reference numerals with "10" added thereto.

[0068] That is, in another embodiment shown in Figure 20, the connection portion between the inner conductor contact (signal contact member) 22 and the center conductor SCa, which is the signal line of the coaxial cable CA, is embedded inside the connection filling portion 21e, which constitutes part of the insulating housing 21, by insert molding.

[0069] When insert molding a configuration in which an electrical connection part is embedded inside the wiring filling part 21e of such an insulating housing 21, first, the inner conductor contact (signal contact member) 22 and the central conductor (signal wire) SCa of the coaxial cable SC are joined by applying ultrasonic vibration similar to the embodiment described above to form a contact assembly CA, and then the contact assembly CA is set inside a mold prepared in advance and insert molded to manufacture the structure.

[0070] According to another embodiment having such a configuration, the connection portion between the inner conductor contact (signal contact member) 22 and the central conductor (signal line) SCa of the coaxial cable SC is held by the insulating housing 21, thereby stabilizing the electrical connection state of the electrical connector and improving its strength.

[0071] [Other embodiments regarding the central conductor (signal line) of the coaxial cable] As described above, the terminal portion of the central conductor (signal conductor) SCa of the coaxial cable SC is formed by plastic deformation into a cross-sectional shape corresponding to the recess THa of the horn TH. However, by forming a recess in the anvil TA arranged opposite the recess THa of the horn TH, or by using molding dies other than the horn TH and anvil TA, it is possible to give the terminal portion of the central conductor (signal conductor) SCa of the coaxial cable SC a cross-sectional shape as shown in each of the following embodiments.

[0072] 21 to 28, each end portion of the central conductors (signal lines) SCa1 ​​to SCa4 of the coaxial cables SC1 to SC4 has first surface portions SCa11 to SCa41 and second surface portions SCa12 to SCa42 that face each other in a direction (positive / negative direction of the Z axis) perpendicular to the extending direction of the central conductors (signal lines) SCa1 ​​to SCa4 (positive / negative direction of the Y axis in the figure). Either one of the first surface portions SCa11 to SCa41 or the second surface portions SCa12 to SCa42 is configured to be connected to the inner conductor contact (signal contact member) 32 shown in FIGS. 29 and 30.

[0073] 21 and 22, the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 according to the embodiment has a "diamond-shaped" cross section in a direction (positive / negative direction of the Z axis) perpendicular to the extending direction (positive / negative direction of the Y axis). More specifically, the lower surface connected to the inner conductor contact (signal contact member) 32 described later is a first surface portion SCa11 consisting of two flat surfaces, and a second surface portion SCa12 arranged to face the first surface portion SCa11 from above is also formed of two flat surfaces.

[0074] Each of the two flat surfaces constituting the first surface portion SCa11 and the second surface portion SCa12 extends in the positive and negative directions of the Y axis of the coaxial cable SC1, specifically in a state of being inclined in a direction intersecting the extending direction (positive and negative directions of the Y axis in the figure) of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 at about 45 degrees. Each of the two flat surfaces has two edges, one edge and the other edge, extending in the extending direction (positive and negative directions of the Y axis in the figure), and one edge of each flat surface is directly connected to each other, so that the cross-sectional shape of the central conductor (signal line) SCa1 ​​in the direction perpendicular to the extending direction (positive and negative directions of the Y axis in the figure) is a "diamond shape".

[0075] The tip surface (lower end surface) of the horn TH1 (or other molding die) that forms the upper surface of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 having such a "diamond-shaped" cross section has a configuration similar to that of the above-mentioned embodiment. For example, the tip surface (lower end surface) of the horn TH1 (or other molding die) shown in Fig. 22 has a recess THa1 consisting of a groove-like portion whose cross section in a direction perpendicular to the extending direction of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 (positive and negative directions of the Y axis in the figure) is recessed in a "V-shape".

[0076] That is, the distance between groove side walls THb1, THb1 consisting of a pair of tapered surfaces constituting the groove-like portion of the recess THa1 in the above-mentioned horn TH1 (or other molding die) is configured to be the maximum groove width at the groove opening at the lower end, and to be continuously reduced in the upward direction from the groove opening toward the bottom of the groove-like portion. The groove side walls THb1, THb1 of this horn TH1 are configured of two flat surfaces extending along the "front-rear direction" (positive and negative directions of the Y axis in the figure), and each of the two flat surfaces constituting the groove side walls THb has two edges consisting of one edge and the other edge extending in the extension direction (positive and negative directions of the Y axis), and one edge of each of the two edges is directly connected to each other.

[0077] Also, although not shown in the figure, a groove-like recess having a "V-shaped" cross-sectional shape in a direction perpendicular to the extension direction (positive and negative directions of the Y-axis) of the central conductor (signal wire) SCa1 ​​of the coaxial cable SC1 is formed on the receiving surface of the anvil (or other molding die), and the distance between groove side walls consisting of a pair of tapered surfaces constituting the groove-like recess is maximum at the groove opening at the upper end, and is configured to continuously decrease in the downward direction from the groove opening toward the bottom of the groove-like portion.

[0078] That is, the groove side wall of the anvil (or other molding die) according to this embodiment is also composed of two flat surfaces extending along the "front-rear direction" (positive and negative directions of the Y-axis in the figure), and each of the two flat surfaces has two edges consisting of one edge and the other edge extending in the "front-rear direction", and one edge of each of the two edges is directly connected to each other. The configuration of the receiving surface of this anvil (or other molding die) is the same in the following embodiments.

[0079] In this way, by making the cross-sectional shape of the recess THa1 provided in the tip surface (lower end surface) of the horn TH1 (or other molding die) V-shaped, when joining is performed by ultrasonic vibration, the ultrasonic vibration is efficiently transmitted to the first surface portion SCa11 of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 and the inner conductor contact (signal contact member) 32 described later via the groove side wall portions THb1, THb1 consisting of the tapered surfaces of the horn TH1.

[0080] In addition, since the two flat surfaces constituting the first surface portion SCa11 of the central conductor (signal conductor) SCa1 ​​of the coaxial cable SC1 form the underside that is connected to the inner conductor contact (signal contact member) 32 described later, the contact area between the central conductor (signal conductor) SCa1 ​​of the coaxial cable SC1 and the inner conductor contact (signal contact member) 32 is increased, and sufficient joining strength can be easily obtained when joining is performed by ultrasonic vibration.

[0081] The central conductor (signal conductor) SCa1 ​​of the coaxial cable SC1 according to the embodiment shown in Fig. 21 and Fig. 22 is connected in a state in which the first surface portion SCa11 constituting the terminal portion of the central conductor (signal conductor) SCa1 ​​is placed from "above" (positive direction of the Z axis in the figure) on the connection portion 32d provided on the inner conductor contact (signal contact member) 32 shown in Fig. 29 and Fig. 30. At this time, the connection portion 32d of the inner conductor contact (signal contact member) 32 is provided with a groove portion 32d1 extending along the "front-rear direction" (positive / negative direction of the Y axis in the figure), which is the extension direction of the central conductor (signal conductor) SCa1 ​​of the coaxial cable SC1.

[0082] The groove 32d1 provided in the inner conductor contact (signal contact member) 32 has a shape corresponding to the first surface SCa11 constituting the terminal portion of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 described above, more specifically, a cross section in a direction perpendicular to the extending direction (positive and negative directions of the Y-axis in the figure) of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 has a "V-shape." Then, the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 is placed in a state of surface contact in the "up and down direction" (positive and negative directions of the Z-axis in the figure) with respect to the groove 32d1 provided in the inner conductor contact (signal contact member) 32, and then ultrasonic vibration is applied to connect them.

[0083] In addition, when the first surface portion SCa11 of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 connected to the internal conductor contact (signal contact member) 32 extends in another cross-sectional shape, such as an "arc shape" or a "polygonal shape", the groove portion 32d1 of the above-mentioned internal conductor contact (signal contact member) 32 will have a cross-sectional shape in a direction perpendicular to the extension direction that is correspondingly "arc shape" or "polygonal shape".

[0084] When connecting an end portion of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 shown in FIG. 21 to the inner conductor contact (signal contact member) 32 according to the embodiment shown in FIG. 29 and FIG. 30, teeth, After arranging the terminal portion of the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 above the connection portion 32d of the inner conductor contact (signal contact member) 32, 、 The entire coaxial cable SC1 is lowered to bring the central conductor (signal line) SCa1 ​​of the coaxial cable SC1 into contact with the connection portion 32d of the internal conductor contact (signal contact member) 32, and then the above-mentioned horn TH and anvil are used to clamp both members together and are fixed together by joining them using ultrasonic vibration. to form a contact assembly. do.

[0085] Next, the contact assembly formed by the above-mentioned ultrasonic vibration bonding process is placed "above" (positive direction of the Z axis in the figure) the contact accommodating space 31c of the insulating housing 31 already assembled to the shield shell 33, as shown in Fig. 31, and the internal conductor contact (signal contact member) 32 of the contact assembly is inserted toward the inside of the contact accommodating space 31c. In this way, the contact assembly is attached, and the contact assembly is attached at this time by forcing the locking portion 32a of the internal conductor contact (signal contact member) 32 constituting the contact assembly into the insulating housing 31.

[0086] In the semi-finished plug connector 30 obtained as described above, the connecting member 33c1 of the shield shell 33 is bent at a substantially right angle to close the shield shell 33, and the first fixed holding plate 33c3 and the second fixed holding plate 33c4 are bent and crimped so as to cover the shield shell 33 from the outside, thereby forming a closed state. 2 and Figure 3 3 As shown in FIG. 1, the electrical connector 30 is completed.

[0087] [Regarding still another embodiment of the central conductor (signal line) of the coaxial cable] 23 and 24, the central conductor (signal line) SCa2 of the coaxial cable SC2 according to the embodiment has a "fan-shaped" cross-sectional shape in a direction perpendicular to the extending direction of the central conductor (signal line) SCa2 (positive and negative directions of the Y-axis in the drawings). More specifically, the first surface portion SCa21 constituting the lower surface connected to the inner conductor contact (signal contact member) 32 described above has two flat surfaces extending in the extending direction of the central conductor (signal line) SCa2 (positive and negative directions of the Y-axis in the drawings).

[0088] Each of the two flat surfaces constituting the first surface portion SCa21 extends in a direction intersecting the extension direction (positive / negative direction of the Y axis in the figure) of the central conductor (signal line) SCa2 of the coaxial cable SC2, specifically in a state inclined at about 45 degrees to the direction intersecting. Each of these two flat surfaces has two edges, one edge and the other edge, extending in the extension direction (positive / negative direction of the Y axis in the figure), and one edge of each flat surface is directly connected to the other.

[0089] In addition, the second surface portion SCa22 constituting the upper surface of the terminal portion of the central conductor (signal line) SCa2 of the coaxial cable SC2 according to this embodiment has an outer shape forming a cross section in a direction perpendicular to the extending direction (positive and negative directions of the Y axis in the figure) of the central conductor (signal line) SCa2, which is a single "curved surface", more specifically, an "arc-shaped" outer shape, and the curved surface curved in an "arc-shaped" state in this cross section extends in the extending direction (positive and negative directions of the Y axis in the figure) of the central conductor (signal line) SCa2. The outermost both ends of the second surface portion SCa22 having such an "arc-shaped" cross section in the radial direction perpendicular to the extending direction are directly connected to the outermost both ends of the first surface portion SCa21 in the radial direction perpendicular to the extending direction.

[0090] In this way, the tip surface (lower end surface) of the horn TH2 (or other molding die) forming the upper surface of the central conductor (signal line) SCa2 of the coaxial cable SC2 having a "fan-shaped" cross section has a recess THa2 consisting of a groove-shaped portion whose cross section in a direction perpendicular to the extending direction of the central conductor (signal line) SCa2 of the coaxial cable SC2 (positive and negative directions of the Y axis in the figure) is recessed into an "arc-shaped" shape, as shown in Fig. 24. More specifically, the distance between the groove side wall portions THb2, THb2 consisting of curved surfaces recessed into an arc-shaped cross section, which constitute the groove-shaped portion of the recess THa2, is set to the maximum groove width at the groove opening at the lower end, and is configured to decrease in a continuous curved linear shape in the upward direction from the groove opening toward the bottom of the groove-shaped portion.

[0091] As in this embodiment, if the recess THa2 provided on the tip surface (lower end surface) of the horn TH2 (or other molding die) is made to have a cross-sectional shape with an "arc-shaped" curved surface, when joining is performed by ultrasonic vibration, the ultrasonic vibration is efficiently transmitted to the first surface portion SCa21 of the central conductor (signal line) SCa2 of the coaxial cable SC2 and the inner conductor contact (signal contact member) 32 described later via the groove side wall portion THb2 consisting of the arc-shaped curved surface of the horn TH2.

[0092] In addition, the center conductor (signal conductor) SCa2 of the coaxial cable SC2 in this embodiment is also connected in a state in which the first surface portion SCa21 constituting the terminal portion of the center conductor (signal conductor) SCa2 is placed from “above” (the positive direction of the Z axis in the figure) on the connection portion 32d provided on the inner conductor contact (signal contact member) 32 shown in Figures 29 and 30. At that time, since the two flat surfaces constituting the first surface portion SCa21 in the center conductor (signal conductor) SCa2 of the coaxial cable SC2 form the underside connected to the above-mentioned inner conductor contact (signal contact member) 32, the contact area between the center conductor (signal conductor) SCa2 of the coaxial cable SC2 and the inner conductor contact (signal contact member) 32 is enlarged, and sufficient joining strength can be easily obtained when joining is performed by ultrasonic vibration.

[0093] [Regarding still another embodiment of the central conductor (signal line) of the coaxial cable] Next, in the central conductor (signal line) SCa3 of the coaxial cable SC3 according to the embodiment shown in Fig. 25 and Fig. 26, the cross-sectional shape in the direction perpendicular to the extending direction of the central conductor (signal line) SCa3 is made to be "polygonal". More specifically, the first surface portion SCa31 of the central conductor (signal line) SCa3 constituting the lower surface connected to the above-mentioned inner conductor contact (signal contact member) 32 has two flat surfaces extending in the extending direction of the central conductor (signal line) SCa (positive and negative directions of the Y axis in the figure). In addition, the second surface portion SCa32 constituting the upper surface of this central conductor (signal line) SCa3 has three flat surfaces extending in the extending direction of the central conductor (signal line) SCa3 (positive and negative directions of the Y axis in the figure).

[0094] Each of the two flat surfaces constituting the first surface portion SCa31 of the above-mentioned central conductor (signal line) SCa3 extends in the positive and negative directions of the Y axis in the figure, in a state inclined in a direction intersecting the extending direction of the central conductor (signal line) SCa3 of the coaxial cable SC3 (positive and negative directions of the Y axis in the figure), specifically, in a direction intersecting at about 45 degrees. Each of these two flat surfaces has two edges consisting of one edge and the other edge extending in the extending direction (positive and negative directions of the Y axis in the figure), and one edge of each of the flat surfaces is directly connected to each other.

[0095] In addition, each of the three flat surfaces constituting the second surface portion SCa32 of the central conductor (signal line) SCa3 also has two edges consisting of one edge and the other edge extending in the extension direction (the positive and negative directions of the Y axis in the figure), and one edge of each of the flat surfaces is directly connected to each other.

[0096] In this way, the tip surface (lower end surface) of the horn TH3 (or other molding die) forming the upper surface of the central conductor (signal line) SCa3 of the coaxial cable SC3 having a "polygonal" cross-sectional shape has a recess THa3 consisting of a groove-shaped portion whose cross-sectional shape in a direction perpendicular to the extending direction of the central conductor (signal line) SCa of the coaxial cable SC (positive and negative directions of the Y axis in the figure) is recessed into a "trapezoid" shape, as shown in Fig. 26. More specifically, the distance between groove side walls THb3, THb3 consisting of a pair of opposing tapered surfaces constituting the groove-shaped portion of the recess THa3 is set to the maximum groove width at the groove opening at the lower end, and continuously reduces in a linear manner in the upward direction from the groove opening toward the bottom of the groove-shaped portion, and the upper edges of these groove side walls THb3, THb3 are indirectly connected to each other via a separate flat surface THb3 extending approximately parallel to the inner conductor contact (signal contact member) 32 described above.

[0097] In other words, the groove side wall portions THb3, THb3, THb3 of the horn TH3 (or other molding die) in this embodiment are composed of three flat surfaces extending along the "front-to-back direction" (the positive and negative directions of the Y axis in the figure), and each of the three flat surfaces has two edges, one of which extends in the extension direction, and one of which is directly connected to the other.

[0098] In this embodiment, if the cross-sectional shape of the recess THa3 provided on the tip surface (lower end surface) of the horn TH3 (or other molding die) is made "trapezoidal," when joining is performed by ultrasonic vibration, ultrasonic vibration is efficiently transmitted to the first surface portion SCa31 of the central conductor (signal line) SCa of the coaxial cable SC and the aforementioned inner conductor contact (signal contact member) 32 via the groove side wall portions THb3, THb3, THb3 consisting of the three flat surfaces of the horn TH3.

[0099] In addition, the center conductor (signal conductor) SCa3 of the coaxial cable SC3 in this embodiment is also connected in a state in which the first surface portion SCa31 constituting the terminal portion of the center conductor (signal conductor) SCa3 is placed from “above” (the positive direction of the Z axis in the figure) on the connection portion 32d provided on the inner conductor contact (signal contact member) 32 shown in Figures 29 and 30. At that time, since the two flat surfaces constituting the first surface portion SCa31 of the center conductor (signal conductor) SCa3 of the coaxial cable SC3 form the underside connected to the inner conductor contact (signal contact member) 32, the contact area between the center conductor (signal conductor) SCa of the coaxial cable SC and the inner conductor contact (signal contact member) 32 is enlarged, and sufficient joining strength can be easily obtained when joining is performed by ultrasonic vibration.

[0100] [Regarding still another embodiment of the central conductor (signal line) of the coaxial cable] Furthermore, in the coaxial cable SC4 according to the embodiment shown in FIGS. 27 and 28, the cross-sectional shape in the direction orthogonal to the extending direction of the central conductor (signal line) SCa4 (the positive and negative directions of the illustrated Y-axis) is also "polygonal", and the first surface portion SCa41 that constitutes the lower surface connected to the internal conductor contact (signal contact member) 32 described above has two flat surfaces extending in the extending direction of the central conductor (signal line) SCa (the positive and negative directions of the illustrated Y-axis). Each of the two flat surfaces that constitute the first surface portion SCa41 extends in the positive and negative directions of the illustrated Y-axis in a state of being inclined in a direction intersecting the extending direction of the central conductor (signal line) SCa4 of the coaxial cable SC4 (specifically, a direction intersecting at about 45 degrees). And each of these two flat surfaces has two edges consisting of one edge and the other edge extending in the extending direction (the positive and negative directions of the illustrated Y-axis), and one edge of each flat surface is directly connected.

[0101] Also, the second surface portion SCa42 that constitutes the upper surface of the central conductor (signal line) SCa4 of the coaxial cable SC4 according to the present embodiment has a single flat surface (horizontal surface) extending in the extending direction of the central conductor (signal line) SCa (the positive and negative directions of the illustrated Y-axis), and the outermost both ends in the width direction (the positive and negative directions of the illustrated X-axis) of the single flat surface (horizontal surface) are indirectly connected to the outermost both ends of the first surface portion SCa41 described above via a pair of other surface portions SCa43, SCa43.

[0102] Here, in the central conductor (signal line) SCa4 of the coaxial cable SC4 according to the present embodiment, the maximum dimension H in the "vertical direction" (the positive and negative directions of the illustrated Z-axis), which is the direction in which the first surface portion SCa41 and the second surface portion SCa42 face each other, is smaller than the maximum dimension W in the "horizontal direction" (the positive and negative directions of the illustrated X-axis) orthogonal to the direction in which the first surface portion SCa41 and the second surface portion SCa42 face each other (H < W). That is, the central conductor (signal line) that had a circular cross-section before processing is formed in a shape compressed in the "vertical direction" (the positive and negative directions of the illustrated Z-axis), and the point of being compressed in this "vertical direction" (the positive and negative directions of the illustrated Z-axis) is the same in other embodiments.

[0103] In this way, the tip surface (bottom end surface) of the horn TH4 (or other molding die) which forms the upper surface of the central conductor (signal line) SCa4 of the coaxial cable SC4, whose cross-sectional shape is "polygonal," is made flat without any recess, as shown in FIG. 28, for example, and the first surface portion SCa41 is directly formed by the flat surface of the horn TH4, and the other surface portion SCa43 described above is formed by appropriately adjusting the amount of pressure (pressing down amount) of the horn TH4.

[0104] In addition, the center conductor (signal conductor) SCa4 of the coaxial cable SC4 in this embodiment is also connected in a state in which the first surface portion SCa41 constituting the terminal portion of the center conductor (signal conductor) SCa4 is placed from “above” (the positive direction of the Z axis in the figure) on the connection portion 32d provided on the inner conductor contact (signal contact member) 32 shown in Figures 29 and 30. At that time, since the two flat surfaces constituting the first surface portion SCa41 of the center conductor (signal conductor) SCa4 of the coaxial cable SC4 form the underside that is connected to the inner conductor contact (signal contact member) 32 described later, the contact area between the center conductor (signal conductor) SCa4 of the coaxial cable SC4 and the inner conductor contact (signal contact member) 32 is enlarged, and sufficient joining strength can be easily obtained when joining is performed by ultrasonic vibration.

[0105] The invention made by the present inventor has been specifically described above based on an embodiment, but it goes without saying that the present invention is not limited to the above-described embodiment and can be modified in various ways without departing from the gist of the invention.

[0106] For example, in the embodiment shown in Figures 1 to 20, the contact assembly CA is attached by press-fitting after the insulating housing 11 is already assembled to the shield shell 13, but it is also possible to attach the contact assembly CA to the insulating housing 11 and then assemble the insulating housing 11 and contact assembly CA to the shield shell 13.

[0107] Furthermore, in the case where the insulating housing 21 is manufactured by insert molding as in the embodiment shown in FIG. 20, the mold structure can be simplified by the latter method, i.e., by attaching the contact assembly CA to the insulating housing 21 and then assembling the insulating housing 21 and contact assembly CA to the shield shell 23.

[0108] Furthermore, the present invention is not limited to single-core coaxial cable connectors such as those in the above-described embodiments, but can also be applied to coaxial cable connectors in which multiple inner conductor contacts are arranged at a predetermined interval, and electrical connectors that combine multiple coaxial cables and insulated cables. [Industrial Applicability]

[0109] As described above, this embodiment can be widely applied to a wide variety of electrical connectors used in various electrical devices. [Explanation of symbols]

[0110] 10,20 Plug connector (electrical connector) 11,21 Insulating housing 11a, 21a Insulating body 11b, 21b Wire connection support part 11c, 21c Contact storage space 11d Bottom wall 21e Wire filling section 12,22 Inner conductor contact (signal contact member) 12a,22a Locking piece 12b, 22b Elastic spring part 12c,22c flat plate part 13,23 Shield Shell 13a, 23a Outer conductor shell (ground contact member) 13b, 23b Shell protrusion 13c, 23c Shell lid 13c1, 23c1 Connecting members 13c2, 23c2 Rear cover part 13c3,23c3 1st fixed holding plate 13c4,23c4 2nd fixed holding plate 13d, 23d Fitting engagement part SC coaxial cable (cable-like signal transmission medium) SCa central conductor (signal line) SCb Outer conductor (shield wire) SCc Dielectric SCd outer sheathing material TA Anvil TH Horn THa Recess THb Groove side wall CA Contact Assembly 30 Plug connector (electrical connector) 31 Insulating housing 31a Insulating body 31b Wire connection support part 31c Contact storage space 31d Bottom wall surface 32 Inner conductor contact (signal contact member) 32a Locking piece 32b Elastic spring part 32c Flat plate part 32d Connection 33 Shield Shell 33a Outer conductor shell (ground contact member) 33b Shell protrusion 33c Shell lid 33c1 Connecting members 33c2 Rear cover part 33c3 1st fixed holding plate 33c4 2nd fixed holding plate 33d Fitting engagement part SC1~SC4 Coaxial cable (cable-like signal transmission medium) SCa1~SCa4 Center conductor (signal line) SCa11 to SCa41 First surface SCa12~SCa42 Second surface SCa43 Other surfaces SCb1~SCb4 Outer conductor (shield wire) SCc1~SCc4 Dielectric SCd1~SCd4 Peripheral coating material 32 Inner conductor contact (signal contact member) 32a Locking piece 32b Elastic spring part 32c Flat plate part 32d Connection

Claims

1. A method for manufacturing an electrical connector comprising the steps of: mounting a signal transmission contact made of a conductive material to a housing made of an insulating material; connecting a central conductor of a coaxial cable to the contact; mounting the housing to a shield shell made of a conductive material; and connecting the shield shell to an outer conductor of the coaxial cable, comprising: a bonding step of applying ultrasonic vibration to the contact before being attached to the housing, in a state where the central conductor of the coaxial cable is in contact with the contact, thereby forming a contact assembly in which the central conductor of the coaxial cable is bonded to the contact, and then performing an assembling step of mounting the contacts of the contact assembly formed in the joining step using ultrasonic vibration into the housing; a step of attaching the contacts of the contact assembly to the housing, and then connecting the shield shell to which the housing is attached to the outer conductor from the outside; In the joining step using ultrasonic vibration, a tip surface of a horn is brought into contact with a single-core central conductor of the coaxial cable, and an anvil is brought into contact with the contact; A method for applying ultrasonic vibration to the contact and the single-core central conductor in a state where the contact and the single-core central conductor are sandwiched between the horn and the anvil, comprising the steps of: a recess for accommodating the single-core central conductor is provided on the tip surface of the horn, and the single-core central conductor is shaped by the recess so that a cross-section of the single-core central conductor in a direction perpendicular to the extension direction has one side connected to the contact and a pair of other sides extending from both ends of the one side, and the spacing between the pair of other sides becomes narrower in the direction away from the contact.

2. 2. The method for manufacturing an electrical connector according to claim 1, wherein in said assembling step, said contacts of said contact assembly are attached by press-fitting into said housing.

3. 2. The method for manufacturing an electrical connector according to claim 1, wherein in said assembling step, said housing is molded by insert molding after said contact assembly is set inside a mold.

4. the recess provided in the horn is a groove-like portion extending along an extending direction of a central conductor of the coaxial cable, the groove-shaped portion has a groove opening having a groove width corresponding to the central conductor of the coaxial cable, and a pair of groove side walls extending from the groove opening toward a groove bottom portion that is the bottom of the groove-shaped portion in a state opposed to each other, 4. The method for manufacturing an electrical connector according to claim 1, wherein the distance between the pair of groove side walls narrows from the groove opening toward the groove bottom.

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