[0001] The invention relates to a method for assembling an electrical connector and to such
an electrical connector. The invention relates particularly to a high-speed data connector
preferably for use in the automotive sector. The requirements for high-speed data
connection systems are increasing greatly. These requirements are being driven by
the growth and complexity of telematic and information applications being introduced,
especially in the automotive sector.
[0002] High-speed data connection systems have to transmit high frequencies. In order to
avoid signal reflections between different wires resulting in losses in the signal,
the impedance, describing the current/voltage ratio, along the entire signal propagation
direction shall be constant. Due to mechanic reasons usually the impedance of a connector
is different from the impedance of a cable. The impedance is largely defined by the
connector geometry, the distance between the contact terminals and the dielectric
constant. In order to achieve a constant impedance in the cable the wires of the cable
are twisted inside an outer covering of the cable. However, the wires are untwisted
within the connector. This can result in a change of the characteristic impedance
in the region of the connector. If the characteristic impedance of the transmission
system is not uniform, a loss in adaptation is observed. In particular, this problem
occurs when high frequency currents are conveyed. Losses in the signals can occur
by reflection.
[0003] In order to avoid these problems
EP 1 193 812 B1 proposes to have a connector with a body and an insulator being inserted within the
body. The insulator has channels for receiving at one end the wires and at another
end terminals wherein the wires and the terminals are electrically connected. The
terminals together with the wires are inserted in a radial direction into the channels.
Therefore, the channels are radially open to an outer circumferential surface of the
insulator. The body is formed as a sleeve with the cylindrical insulator being inserted
in this sleeve-like body in an axial direction. To ensure that via the complete transmission
system the impedance is nearly the same, the channels are arranged symmetrically with
regard to a longitudinal axis of said cylindrical insulator, according to a characteristic
impedance of the cable.
[0004] Other connectors having an insulator with radially open channels for inserting terminals
in radial direction are disclosed in
EP 0 444 478 A1 and
EP 1 825 575 B1. Both publications disclose connectors having a body in which the insulator together
with the terminals is inserted.
[0005] Object of the present invention is to provide a method for assembling a connector
and such a connector having less parts and enabling an easy method for assembling.
[0006] The object is solved by a method according to claim 1 and a connector according to
claim 5. Preferred embodiments of the invention are disclosed in the dependent subclaims.
[0007] The invention is directed to a method for assembling an electrical connector wherein
the connector comprises a housing and at least one receiving arrangement comprising
a channel extending in the housing parallel to a longitudinal axis, a wire, having
a conductor and an insulation, and a terminal. The receiving arrangement is provided
in the housing. In contrary to the prior art the connector does not have separate
elements such as a central insulator being mounted to a sleeve-like outer body. Since
the channels extend in an axial direction through the housing the terminals have to
be inserted in axial direction. The channels are radially closed and just have an
opening at a front end and an opening at a back end of the housing for inserting the
a terminal and a wire, respectively. Further, in order to provide for a simple terminal
design without any elastic lances on the terminal to secure the terminal within the
housing the terminal has to be inserted into the channel in an axial direction from
the front side of the housing until a stop face of the terminal comes into supporting
contact to a supporting face of the housing. In addition, the wires have to be inserted
from the back side of the housing in an axial direction into the channels. This results
to the requirement that before the terminal be contacted to the conductor of the wire,
the wire has to be passed through the channel of the housing. Afterwards, the terminal
can be connected to the conductor of the wire. Preferably, the wire is passed through
the channel with a front side of the wire being completely insulated, i.e. the insulation
of the front end of the wire is not stripped off the conductor. This makes the step
of inserting the wire into the channel easier. The insulation can be stripped off
the conductor after the wire has been pushed and passed through the channel. However,
alternatively, the insulation of the wire at the front end can be stripped-off prior
pushing them through the channel. As soon as the terminal has been connected to the
conductor of the wire, the wire is being pulled back until the terminal is supported
against the support face of the housing.
[0008] Inserting the terminal means, that at least a part of the terminal is received within
the channel. The terminal partly projects out of the channel. Alternatively, the entire
terminal can be received within the channel without a part of the terminal projecting
out of the channel. The wire, inserted into the channel, is received with a front
end within the channel while a back end of the wire leads out of the channel at the
back side of the housing.
[0009] In order to protect the terminal against outer influences avoiding for example a
deformation of the terminal, a front cover can be provided which is mounted to a front
side of the housing and which covers the terminal and the channel. The front cover
additionally makes sure that the terminals cannot moved out of the channels. The front
cover is a stop against movement in a direction opposite to the insertion direction
of the terminals. In order to enable the insertion of a counter-terminal into the
housing to make contact with the terminal the front cover has an opening in alignment
to the channel through which the counter-terminal can be passed through. The opening
being part of the receiving arrangement.
[0010] Preferably, the terminal is connected to the conductor by crimping. Alternatively
the terminal can be soldered or connected to the conductor by any other well known
method.
[0011] The electrical connector comprises connection means on the housing for connecting
the housing to a counter-connector. The means can be for instance locking arms projecting
from an outer circumferential surface of the housing and which can be locked to locking
means of a counter-connector, such like outer projections or notches of the counter-connector.
The at least one receiving arrangement is arranged in a channel portion of the housing
wherein the housing comprising the channel portion and the means for connecting the
housing to a counter-connector is formed integrally in one piece. This reduces the
number of parts of the electrical connector resulting in a simpler design and in a
less complex assembly.
[0012] Preferably, a front cover is mounted to the housing at the front side of the housing
and the receiving arrangement comprises an opening in the front cover in alignment
with the channel. The opening enables a counter-terminal to be inserted through the
opening reaching into the housing in order to come into electrical contact with the
terminal.
[0013] The wire can be inserted into the channel from a back side of the housing. The terminal
can be inserted into the channel from a front side of the housing, i.e. from an opposite
side than the wire.
[0014] The terminal may have a contact portion to be mated with a counter-terminal for electrical
connection and a connection portion to be connected to the conductor of the wire.
The conductor of the wire can be crimped, soldered or in other well known manner be
connected to the connection portion.
[0015] The terminal may have at least one projection, preferably in form of an annular flange,
defining the stop face. The projection is arranged on an outer surface of the terminal
projecting in a substantial radial direction relative to a longitudinal axis of the
terminal.
[0016] The contact portion and the connection portion may be arranged on opposite sides
of the at least one projection.
[0017] The channel may have a radial step defining the support face. This radial step can
be formed in the transition between two channel portions having different dimensions
in a radial direction. The channel may be circular in cross-section. The step may
extend partially or entirely around a circumference of the channel and around the
terminal.
[0018] The terminal may project out of the channel on the front side of the housing.
[0019] The front cover may have a receiving chamber receiving and radially supporting the
terminal, in particular, the part of the terminal that projects out of the channel
of the housing. The receiving chamber and the channel are aligned to each other and
are receiving the terminal together.
[0020] Preferably, a plurality of receiving arrangements is provided, for example four receiving
arrangements. The receiving arrangements are further preferably arranged, viewed in
a cross-section perpendicular to the longitudinal axis, on a circle and being distributed
equidistant.
[0021] A preferred embodiment is described with reference to the accompanying drawings.
Figure 1 shows a perspective view of the connector 1 according to the invention;
Figure 2 is a longitudinal section of the connector 1, and
Figure 3 a front view of the connector 1.
[0022] The connector 1 comprises a one-piece housing 2 with a front side 3 and a back side
4. At the front side 3 the housing 2 has a front portion 5. It has a substantially
cylindrical shape. The front portion 5 has an elastic locking arm 6 on its outer circumference.
The front portion 5 is adapted to be inserted into a receptacle of a counter-connector,
e.g. in the form of a socket (not shown). The locking arm 6 can be locked to the counter-connector
by a cam 7 on the outside of the locking arm 6, wherein the cam 7 can be locked into
a locking notch of the counter-connector.
[0023] The front portion 6 has a cavity 8 open to the front side 3 of the housing 2 and
being centered relative to a longitudinal axis L of the housing 2. The cavity 8 receives
a front cover 9 which has a cavity 10 open to the front side 3 of the housing 2 and
being centered relative to the longitudinal axis L. The cavity 10 of the front cover
9 can receive a portion of the counter-connector having counter-terminals.
[0024] The front cover 9 is provided with four openings 11 each for passing through one
counter-terminal.
[0025] On the back side 4 of the housing 2 a cable 12 is provided comprising four wires
13 being twisted. Each wire 13 is inserted from the back side 4 of the housing 2 into
channels 14 of the housing 2. The channels 14 are located in a channel portion 26
of the housing 2. The channels 14 penetrate the housing 2 from the back side 4 to
the front side 3 and are open towards the cavity 8 of the front portion 5 of the housing
2. Further, the connector 1 comprises four terminals 15 inserted from the front side
3 of the housing 2 into the channels 14 and being connected to conductors 27 of the
wires 13. Each channel receives, at least partly, one terminal and one wire being
connected to said terminal.
[0026] The terminals 15 are partly inserted into the channels 14 and project over a bottom
face 18, which is perpendicular to the longitudinal axis L, of the cavity 8 of the
front portion 5 into the cavity 8. The front cover 9 has a covering portion 16 with
receiving chambers 17 for each of the terminals 15 so that the parts of the terminals
15 which project out of the channels 14 and into the cavity 8 are received within
the receiving chambers 17 of the front cover 9. Each of the openings 11 is aligned
with one of the channels 14 so that a counter-terminal can be inserted into the opening
11 into the receiving chamber 17 in order to get into electrical contact with the
terminals 15.
[0027] The channels 14 each have a first part 19 open to the front side 3 of the housing
2 and a second part 20 open to the back side 4 of the housing 2. The first part 19
of the channels 14 has a greater diameter than the second part 20 so that between
the first part 19 and the second part 20 the step is formed defining a support face
21 facing in the direction of the front side 3. The terminals 15 each have a flange
22 having a ring-shape outer circumference. The flange 22 defining a stop face 23
facing the support face 21 of the housing 2. In the position as shown in Figure 2
the stop face 23 of the terminals 15 is in supporting contact to the support face
21 of the channels 14 so that the terminals 15 cannot be pushed further into the channel
14 from the front side 3.
[0028] One of the terminals 15 is shown in more detail in Figure 4. The terminal 15 has
a connection portion 24 for connecting the terminal 15 to a conductor 27 of one of
the wires 13. The connection portion 24 is formed as a crimping portion for crimping
the terminal 15 to the conductor 27. However, alternatively the connection portion
24 can also be a portion for soldering the terminal 15 to the conductor 27 or to connect
the terminal 15 in another well known manner to the conductor 27.
[0029] Further, the terminal 15 has a contact portion 25 in the form of a hollow tube. At
the end of the terminal 15 directed towards the front side 3 spring arms 28 are provided.
A counter-terminal of the socket connector can be inserted into the hollow terminal
15 from a front side and between the spring arms 28 wherein the spring arms 28 are
clamping the counter-terminal.
[0030] The terminal further has a flange 22 formed into the tube like portion of the terminal
15. Hence, the flange 22 provides for a very robust solution for locking the terminal
15 within the channel 14, by supporting the stop face 23 of the flange 22 against
the support face 21 of the housing. The connection portion 24 and the contact portion
25 are arranged on opposite sides of the flange 22.
[0031] The housing 2 has a one-piece design, that means the channel portion 26 of the housing
2 is integral with the locking arm 6, which locking arm 6 is a means for connecting
the housing 2 to a counter-connector (socket connector). Preferably, the housing 2
is molded from a resin material in one-piece so that the connector 1 has a low number
of components and can be produced less expansive. In addition, there is no need for
assembling a high number of components.
[0032] Figures 5 to 11 show the method for assembling the electrical connector. In a first
step (Figure 5) the single wires 13 are pushed through the channels 14 from the back
side 4 of the housing 2 until they project out of the channels 14 on the front side
3 of the housing 2. The wires 13 each have a central conductor 27 and an insulation
29 surrounding the conductor 27. Preferably, the single wires 13 are pushed through
the channels 14 with the insulation covering the conductor 27 on a front end 30 of
the wire 13 which projects out of the channels 14. After all wires 13 have been pushed
through the channels 14 (Figure 6) the insulation is being stripped off the conductors
27 at the front ends 30 of the wires 13 (Figure 7). Then the terminals 15 are connected
with the conductors 27 of the wires 13, for instance by crimping (Figure 8). Afterwards,
the wires 13 are pulled back into the channels 14 until the stop faces 23 of the terminals
15 come into contact to the support faces 21 of the channels 14 (Figure 9). When all
of the wires 13 have been pulled back the front cover 9 is mounted into the cavity
8 of the front portion 5 of the housing 2 (Figure 10).
[0033] At the end the wires 13 are twisted closely together. For cost optimization a shielding
around the twisted wires can be omitted.
Reference numerals
1 |
connector |
2 |
housing |
3 |
front side |
4 |
back side |
5 |
front portion |
6 |
locking arm |
7 |
cam |
8 |
cavity |
9 |
front cover |
10 |
cavity |
11 |
opening |
12 |
cable |
13 |
wire |
14 |
channel |
15 |
terminal |
16 |
covering portion |
17 |
receiving chamber |
18 |
bottom face |
19 |
first part |
20 |
second part |
21 |
support face |
22 |
flange |
23 |
stop face |
24 |
connection portion |
25 |
contact portion |
26 |
channel portion |
27 |
conductor |
28 |
spring arm |
29 |
insulation |
30 |
front end |
L |
longitudinal axis |
1. Method for assembling an electrical connector (1) the connector comprising a housing
(2); and
at least one receiving arrangement in the housing (2) comprising a channel (14) extending
in the housing (2) parallel to a longitudinal axis (L), a wire (13), having a conductor
(27) and an insulation (29), and a terminal (15); wherein the terminal (15) has a
stop face (23) to be supported against a support face (21) of the housing (2);
the method comprising the steps of:
inserting the wire (13) in axial direction through the channel (14) from a back side
(4) of the housing (2) until a front end (30) of the wire (13) projects out of the
channel (14) on the front side (3) of the housing (2);
connecting the terminal (15) to the conductor (27); and
pulling back the wire (13) until the stop face (23) of the terminal (15) is supported
against the support face (21) of the housing (2).
2. Method according to claims 1,
characterized in
that a front cover (9) is mounted to a front side (3) of the housing (2).
3. Method according to any one of the preceding claims,
characterized in
that after the wire (13) has been passed through the channel (14) the insulation (29)
is stripped off the conductor (27) at the front end (30) of the wire (13).
4. Method according to any one of the preceding claims,
characterized in
that the terminal (15) is connected to the conductor (27) by crimping.
5. Electrical connector comprising:
a housing (2) with connection means (6) for connecting the housing (2) to a counter-connector;
and
at least one receiving arrangement in a channel portion (26) of the housing (2) the
receiving arrangement comprising a channel (14) extending parallel to a longitudinal
axis (L) within the housing (2), a wire (13) inserted into the channel (14) in axial
direction and a terminal (15) connected to the wire (13) and inserted into the channel
(14) in axial direction;
wherein the terminal (15) has a stop face (23) supported against a support face (21)
of the housing (2) and
wherein the housing (2) comprising the channel portion (26) and the means (6) for
connecting the housing (2) to a counter-connector is formed integrally in one piece.
6. Electrical connector according to claims 5,
characterized in
that a front cover (9) is mounted to the housing (2) at the front side (3) of the housing
(2),
that the receiving arrangement further comprises an opening (11) in the front cover (9)
in alignment with the channel (14).
7. Electrical connector according to any one of claims 5 or 6,
characterized in
that the wire (13) is inserted into the channel (14) from a back side (4) of the housing
(2).
8. Electrical connector according to any one of claims 5 to 7,
characterized in
that terminal (15) is inserted into the channel (14) from a front side (3) of the housing
(2).
9. Electrical connector according to any one of claims 5 to 8,
characterized in
that the terminal (15) has a contact portion (25) to be mated with a counter-terminal
for electrical connection and a connection portion (24) to be connected to the conductor
(27) of the wire (13).
10. Electrical connector according to any one of claims 5 to 9,
characterized in
that the terminal (15) has at least one projection, preferably in form of an annular flange
(22), defining the stop face (23).
11. Electrical connector according to claims 10,
characterized in
that the contact portion (25) and the connection portion (24) are arranged on opposite
sides of the at least one projection (22).
12. Electrical connector according to any one of claims 5 to 11,
characterized in
that the channel (14) has a radial step defining the support face (21).
13. Electrical connector according to any one of claims 5 to 12,
characterized in
that the terminal (15) projects out of the channel (14) on the front side (3) of the housing
(2).
14. Electrical connector according to claims 13,
characterized in
that the front cover (9) has a receiving chamber (17) receiving and radially supporting
the part of the terminal (15) that projects out of the channel (14) of the housing
(2).
15. Electrical connector according to claims 14,
characterized in
that the receiving chamber (17) and the channel (14) are in alignment to each other.
16. Electrical connector according to any one of claims 5 to 15,
characterized in
that a plurality of receiving arrangements is provided.