Right-Angle Plug Connector Assembly With Deep-Drawn Outer Conductor
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Solution Overview
Problem
Existing right-angle plug connectors face challenges in transmitting high-frequency electrical signals efficiently and are complex to assemble, particularly due to the one-piece design of the outer-conductor contact element, which complicates final assembly and requires improved electrical and mechanical properties.
Innovation Solution
The outer-conductor contact element is formed in one piece from a deep-drawn sheet-metal part, featuring a crimping portion, a sleeve-shaped contact portion, and a trough-shaped transition region, with shielding flaps that allow for simplified assembly and enhanced electromagnetic shielding, while maintaining a seamless transition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer-conductor contact element is formed in one piece from a stamped and bent part, then good electrical properties and shielding efficiency are achieved, but final assembly becomes more difficult and complex
Solution Approach 1:
The outer-conductor contact element is divided into multiple separate components: a crimping portion, a contact portion, and a transition region. These segments can be manufactured separately and then assembled together, reducing the complexity of final assembly while maintaining the electrical properties and shielding efficiency of a one-piece design through careful design of the interfaces between segments.
2Object-affected harmful factors
If the outer-conductor contact element is formed in one piece, then electromagnetic shielding is enhanced, but manufacturing and assembly cost-effectiveness is reduced
Solution Approach 1:
Dividing the outer-conductor contact element into separate crimping portion, contact portion, and transition region allows each segment to be manufactured using optimized processes suitable for its specific requirements, then assembled together. This maintains the electromagnetic shielding effectiveness through proper design of the segmented structure while improving manufacturing flexibility and cost-effectiveness.
Solution Approach 2:
The transition region is designed to serve multiple functions: it connects the crimping portion to the contact portion, provides structural support, maintains electromagnetic shielding, and facilitates assembly. This multi-functionality reduces the need for additional separate components, thereby maintaining cost-effectiveness while achieving enhanced shielding.
3Volume of moving object
If the plug connector is made compact to save installation space and weight, then space and weight requirements are met, but assembly difficulty increases
Solution Approach 1:
The segmented outer-conductor contact element is designed to nest efficiently within the compact plug connector housing. The crimping portion, contact portion, and transition region are arranged to maximize space utilization, allowing the connector to meet compact size requirements while the modular segmentation simplifies assembly by allowing components to be installed in a logical sequence.
Data Source
AI summary
The invention relates to an outer-conductor contact element (2) for a right-angle plug connector (1). The right-angle plug connector (1) has a crimping portion (9) for pressing the outer-conductor contact element (2) onto an electric cable (4), said crimping portion (9) having a free end (10), which is open at the end side, for receiving the cable (4). The right-angle plug connector (1) further has a sleeve-like contact portion (12) having a free end (13), which is open at the end side, for establishing a connection with a corresponding mating plug connector, wherein an exit angle (α) is formed between a first longitudinal axis (L1) of the contact portion (12) and a second longitudinal axis (L2) of the crimping portion (9). The right-angle plug connector (1) also has a tub-shaped transition region (14) which, starting from the crimping portion (9), extends along the second longitudinal axis (L2) of the crimping portion (9) as far as the contact portion (12). The crimping portion (9), the contact portion (12) and the transition region (14) are formed in one piece from a deep-drawn sheet-metal part.