CN110896185A - 带角度的电连接器组件及其制造方法 - Google Patents

带角度的电连接器组件及其制造方法 Download PDF

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CN110896185A
CN110896185A CN201910863598.XA CN201910863598A CN110896185A CN 110896185 A CN110896185 A CN 110896185A CN 201910863598 A CN201910863598 A CN 201910863598A CN 110896185 A CN110896185 A CN 110896185A
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terminal
attachment surface
attachment
electrical connector
connector assembly
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M·L·佩恩
J·M·莱尼
B·马加洛斯
J·R·莫瑞罗
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Aptiv Technologies Ltd
Delphi Technologies Inc
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    • H01R9/00Structural associations of a plurality of mutually-insulated electrical connecting elements, e.g. terminal strips or terminal blocks; Terminals or binding posts mounted upon a base or in a case; Bases therefor
    • H01R9/03Connectors arranged to contact a plurality of the conductors of a multiconductor cable, e.g. tapping connections
    • H01R9/05Connectors arranged to contact a plurality of the conductors of a multiconductor cable, e.g. tapping connections for coaxial cables
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/16Laser beams
    • B29C65/1603Laser beams characterised by the type of electromagnetic radiation
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    • BPERFORMING OPERATIONS; TRANSPORTING
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Abstract

一种电连接器组件,包括:电端子,该电端子具有附接端和连接端;第一端子外壳,该第一端子外壳具有第一腔体,其中设置有附接端。该第一腔体限定了供连接端延伸穿过的端子延伸开口。该组件还包括第二端子外壳,该第二端子外壳具有第二腔体,其中设置有连接端。该第二腔体限定了供连接端穿过而被接纳的端子接纳开口。第一端子外壳限定了围绕端子延伸开口的第一附接表面,并且第二端子外壳限定了围绕端子接纳开口的第二附接表面。第一附接表面被密封到第二附接表面。第一附接表面相对于纵向轴线形成第一角度,且第二附接表面相对于横向轴线形成第二角度。

Description

带角度的电连接器组件及其制造方法
相关申请的交叉引用
本申请要求2018年9月13日提交的美国临时专利申请第62/730,694号的权益,其全部内容以参见的方式纳入本文。
技术领域
本发明总体上涉及电连接器,特别涉及一种电连接器,其中附接到线材线缆的端部和构造成接纳配合连接器的另一端部相对于彼此成角度。
背景技术
同轴线缆连接器组件已经用于许多汽车应用,诸如全球定位***(GPS)、信息娱乐***和气囊***。同轴线缆通常包括由外屏蔽层导体、内中心导体、电介质和绝缘护套。同轴线缆的外导体和内导体通常通过插座和插头连接器与配合的同轴线缆电联接。这种传统的同轴线缆连接器在本领域中是已知的。
为了使各种类型的连接器标准化并且由此避免混淆,已经建立了某些行业标准。其中一个标准称为FAKRA。FAKRA是德国标准化研究院中的汽车标准委员会(德语为“Deutsches Institut für Normung”,缩写DIN最为知名),代表了汽车领域的国际标准化利益。FAKRA标准提供了用于正确连接器附接的、基于键和颜色编码的***。在FAKRA连接器中,类似的插座键只能连接到的类似的插头键槽。借助插座外壳上的FAKRA限定的卡扣和插头外壳上的协配的闭锁,便于连接器外壳的可靠定位和锁定。FAKRA标准包含在由美国汽车研究委员会(USCAR)发布的USCAR-18标准中。
诸如符合FAKRA标准的那些直角的密封电连接器组件通常需要两件式端子。与单件式端子相比,这些两件式端子可能具有较差的电性能。
仍然需要一种可以容纳单件式端子的直角的密封电连接器。
在背景部分中论述的主题不应仅由于其在背景部分中被提及而被认定是现有技术。类似地,背景部分中提到的、或与背景部分的主题相关的问题不应当被认为之前已在现有技术中被发现。背景部分中的主题仅代表不同的方案,它们本身也可以是发明。
发明内容
根据本发明的一个实施例,提供了一种电连接器组件。该电连接器组件包括电端子,该电端子具有沿纵向轴线延伸的附接端和沿横向轴线延伸的连接端,该附接端构造成附接到线材线缆,该连接端构造成附接到对应的配合端子。电连接器组件还包括第一端子外壳,该第一端子外壳具有沿纵向轴线延伸的第一腔体,其中设置有附接端。该第一腔体限定了供线材线缆延伸穿过的线缆开口,并且限定了供连接端延伸穿过的端子延伸开口。电连接器组件还包括第二端子外壳,该第二端子外壳具有沿横向轴线延伸的第二腔体,其中设置有连接端。该第二腔体限定了供连接端穿过而被接纳的端子接纳开口和构造成接纳对应的配合端子的配合开口。第一端子外壳限定了围绕端子延伸开口的第一附接表面,并且第二端子外壳限定了围绕端子接纳开口的第二附接表面。第一附接表面被密封到第二附接表面。第一附接表面相对于纵向轴线形成第一角度,且第二附接表面相对于横向轴线形成第二角度。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,第二角度与第一角度互补。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,第一角度的第一角度值为约45度,第二角度的第二角度值为约45度。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,第一附接表面限定了围绕端子延伸开口的周向脊,并且第二附接表面限定了围绕端子接纳开口的周向沟槽,其中接纳有周向脊。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,使用红外激光焊接工艺将周向脊焊接到周向沟槽。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,第一附接表面焊接到第二附接表面,由此在第一端子外壳与第二端子外壳之间形成防水的接合部。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,使用激光焊接工艺将第一附接表面焊接到第二附接表面。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,第一端子外壳由第一材料形成,第二端子外壳由不同于第一端子外壳的第二材料形成。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,第一材料是红外线穿透的,且第二种材料是红外线吸收的。
在具有先前段落的电连接器组件的一个或多个特征的示例性实施例中,附接端的纵向轴线基本上垂直于连接端的横向轴线。
根据本发明的一个实施例,提供了制造电连接器组件的方法。
该方法包括以下工序:
a)提供电端子,该电端子具有沿纵向轴线延伸的附接端和沿横向轴线延伸的连接端,该附接端构造成附接到线材线缆,该连接端构造成附接到对应的配合端子;
b)提供第一端子外壳,该第一端子外壳具有沿纵向轴线延伸的第一腔体,其中设置有附接端,该第一腔体限定了供线材线缆延伸穿过的线缆开口,并且限定了供连接端延伸穿过的端子延伸开口;
c)提供第二端子外壳,该第二端子外壳具有沿横向轴线延伸的第二腔体,其中设置有附接端,该第二腔体限定了供连接端穿过而被接纳的端子接纳开口和构造成接纳对应的配合端子的配合开口,其中第一端子外壳限定了围绕端子延伸开口的第一附接表面,并且第二端子外壳限定了围绕端子接纳开口的第二附接表面;
d)将电端子的附接端插设在第一端子外壳的第一腔体内;
e)将电端子的连接端插设在第二端子外壳的第二腔体内;以及
f)将第一附接表面密封到第二附接表面。
在具有先前段落的方法的一个或多个特征的示例性实施例中,第一附接表面限定了围绕端子延伸开口的周向脊,并且第二附接表面限定了围绕端子接纳开口的周向沟槽。该方法还包括将周向脊设置在周向沟槽内的步骤。
在具有先前段落的方法的一个或多个特征的示例性实施例中,通过使用红外激光焊接工艺将周向脊焊接到周向沟槽来执行步骤f):将第一附接表面密封到第二附接表面。
在具有先前段落的方法的一个或多个特征的示例性实施例中,通过将第一附接表面焊接到第二附接表面来执行步骤f):将第一附接表面密封到第二附接表面。
在具有先前段落的方法的一个或多个特征的示例性实施例中,使用激光焊接工艺来执行步骤f):将第一附接表面密封到第二附接表面。
在具有先前段落的方法的一个或多个特征的示例性实施例中,第一端子外壳由第一材料形成,第二端子外壳由不同于第一端子外壳的第二材料形成。
在具有先前段落的方法的一个或多个特征的示例性实施例中,第一材料是红外线穿透的,且第二种材料是红外线吸收的。
在具有先前段落的方法的一个或多个特征的示例性实施例中,附接端的纵向轴线基本上垂直于连接端的横向轴线。
附图说明
现将参考附图并借助示例来描述本发明,附图中:
图1是根据本发明的一个实施例的与配合连接器组件接合的带角度的电连接器组件的立体图;
图2是根据本发明的一个实施例的图1的带角度的电连接器组件的分解图;
图3是根据本发明的一个实施例的图1的带角度的电连接器组件的剖面侧视图;
图4是根据本发明的一个实施例的图1的带角度的电连接器组件的剖面俯视图;
图5是根据本发明的一个实施例的图1的带角度的电连接器组件的剖面端视图。
图6是根据本发明另一实施例的制造图1的带角度的电连接器组件的方法的流程图。
具体实施方式
现在具体参照实施例,实施例的各示例在附图中示出。在下面的描述中,阐述了许多具体细节以便于提供对各个描述的实施例的透彻理解。然而,本领域技术人员将认识到没有这些具体细节也可实践各个描述的实施例。在另外的例子中,并未对人们所熟知的方法、工艺、部件、回路及相互关系进行详细描述,以免不必要地使实施例的各方面变得不清楚。
图1示出了用于互连例如同轴线缆的线材线缆102的电连接器***100。所示的连接器***包括直角的同轴连接器104和直的配合同轴连接器106。图1中所示的连接器各自符合FAKRA标准。
如图2和图3中最佳所示,直角的连接器104包括直角的同轴电端子(下文中称为端子108),其具有沿纵向轴线X延伸的附接端110和沿横向轴线Y延伸的连接端112,附接端110构造成附接到线材线缆102,连接端112构造成附接到包含在配合连接器106中的对应的配合端子(未示出)。由于这是直角的端子,附接端110的纵向轴线X基本上垂直于连接端112的横向轴线Y.当在本文中使用时,大致上垂直意味着绝对垂直的±5度。
端子108包含在电绝缘的两部分的外壳内。第一端子外壳(下文中称为第一外壳114)具有沿纵向轴线X延伸的第一腔体116,其中设置有附接端110。第一腔体116限定了两个开口:供线材线缆102延伸穿过的线缆开口118和供直角的端子的连接端112延伸穿过的端子延伸开口120。第二端子外壳(下文中称为第二外壳122)具有沿横向轴线Y延伸的第二腔体124,其中设置有附接端110。第二腔体124还限定两个开口:供连接端112穿过而被接纳的端子接纳开口126和构造成接纳对应的配合连接器106的配合开口128。第一外壳114限定了周向地围绕端子延伸开口120的第一附接表面130。第二外壳122限定了围绕端子接纳开口126的第二附接表面132。第一附接表面130密封到第二附接表面132,由此在第一外壳114与第二外壳122之间提供防水的、优选为气密的密封。第一附接表面130相对于纵向轴线X形成第一锐角134,且第二附接表面132相对于横向轴线Y形成第二锐角136。由于这是直角的连接器104,因此第二锐角136与第一锐角134互补,即第一锐角134的第一角度值与第二锐角136的第二角度值之和为约90度。优选地,第一锐角134的第一角度值为约45度,且第二锐角136的第二角度值为约45度。如本文所使用的,“约”特定角度值意味着所述特定角度值的±5度。
第一附接表面130限定了围绕端子延伸开口120的周向脊(在下文中称为脊138),并且第二附接表面132限定了围绕端子接纳开口126的周向沟槽(下文中称为沟槽140),其中接纳有脊138。通过使用红外激光焊接工艺将脊138的上表面142焊接到沟槽140的下表面144来将第一附接表面130焊接到第二附接表面132。第一外壳114由诸如掺杂有红外吸收颜料的聚合物之类的红外吸收材料形成,且第二外壳122由诸如聚乙烯或聚丙烯之类的透红外线材料形成。当红外激光能量施加到脊138的区域时,该激光能量穿过第二外壳122并被第一外壳114的脊138吸收,由此在第一外壳114与第二外壳122之间形成熔化区段146,如图3、图4、图5所示。能够预先形成这种红外激光焊接的红外焊接***是可从康涅狄格州丹伯里市的布兰森超声波公司(Branson Ultrasonics Corporation of Danbury,Connecticut)获得的同时通过红外传输(SIMULTANEOUS THROUGH TRANSMISSION
Figure BDA0002200578230000061
)焊接***。
如图3所示,直角的连接器104还包括顺应性线缆密封件148和顺应性外壳密封件150以阻止可能腐蚀端子108的诸如水、灰尘或电解质之类的环境污染物进入到腔体中。
在现有设计的连接器设计中,直角的FAKRA顺应性连接器使用了单件式外壳,该单件式外壳包含两件式端子屏蔽层从而满足环境密封要求。发现这种构造是昂贵的,并且由于两件式端子而可能表现出不稳定的连接特性。
图1-图5中所示的直角的连接器104的两件式外壳114、122的成角度的分型线提供了允许直接插设单件式端子护罩的益处,该单件式端子屏蔽层提供比两件式端子更可靠的连接性能。脊138和沟槽140的红外激光焊接特征允许第一外壳114与第二外壳122之间的接缝提供防水或气密密封。
图6示出了根据本发明一个实施例的制造端子108的方法200的示例。该方法200包括下列步骤:
提供电端子的步骤202,该步骤包括提供端子108,该端子108具有沿纵向轴线X延伸的附接端110和沿横向轴线Y延伸的连接端112,附接端110构造成附接到线材线缆102,连接端112构造成附接到对应的配合端子。附接端110的纵向轴线X基本上垂直于连接端112的横向轴线Y;
提供第一端子外壳的步骤204,该步骤包括提供第一外壳114,该第一外壳114具有沿纵向轴线X延伸的第一腔体116,其中设置有附接端110,该第一腔体116限定了供线材线缆102延伸穿过的线缆开口118并且限定了供连接端112延伸穿过的端子延伸开口120。
提供第二端子外壳步骤206,该步骤包括提供第二外壳122,该第二外壳122具有沿横向轴线Y延伸的第二腔体124,其中设置有附接端110,该第二腔体124限定了供连接端112穿过而被接纳的端子接纳开口126和构造成接纳对应的配合连接器106的配合开口128,其中第一外壳114限定了围绕端子延伸开口120的第一附接表面130,并且第二外壳122限定了围绕端子接纳开口126的第二附接表面132。
将电端子插设在第一端子外壳和第二端子外壳内的步骤208,该包括将端子108的附接端110插设在第一外壳114的第一腔体116内,并且将端子108的连接端112插设在第二外壳122的第二腔体124内;
第一附接表面130可限定围绕端子延伸开口120的脊138,并且第二附接表面132限定了围绕端子接纳开口126的沟槽140。在沟槽内设置脊的步骤210,该步骤是步骤202的可选子步骤,其包括将脊138设置在沟槽140内;以及
将第一端子外壳密封到第二端子外壳的步骤212,该步骤包括将第一附接表面130密封到第二附接表面132。步骤212可以通过例如通过激光焊接工艺将第一附接表面130焊接到第二附接表面132来执行。步骤212可以通过使用红外激光焊接工艺将脊138焊接到沟槽140来执行。在这种情况下,第一外壳114由第一材料形成,且第二外壳122由与第一外壳不同的第二材料形成。第一材料基本上是红外线穿透的,且第二种材料是红外线吸收的。
虽然本文呈现的示例性电连接器是直角的构造,但是可以设想本发明的其它实施例,其在附接端110和端子108的连接器端之间的角度在1度到179度的范围内。
尽管已就其优选实施例描述了本发明,但本发明不旨在受此限制,而是仅限制于在随后的权利要求书中提出的范围。例如,以上描述的实施例(和/或其各个方面)可彼此组合地使用。此外,可作各种改型以使得具体的情形或材料适应本发明的教导,而不偏离其主要范围。本文描述的尺寸、类型、各个部件的定向以及各个部件的数量和位置旨在限定特定实施例的参数,不意味着限制,而仅为原型实施例。
在阅读了以上描述后,在权利要求精神和范围内的各种]其它实施例和变型对本领域的普通技术人员来说是显然的。因此,本发明的范围仅由所附权利要求书、以及这些权利要求所涵盖的等同物的全部范围所限定。
如此处使用的,一个或多个摂包括由一个元件执行的功能、如以分布的形式由超过一个元件执行的功能,由一个元件执行若干功能,由若干元件执行若干功能,或以上这些的组合。
因此理由,尽管在一些实施例中使用了术语第一、第二等被用来描述不同的元件,但是这些元件不应被这些术语限制。这些术语仅用来将一个元件区别于另一个元件。例如,第一触件可被称为第二触件,类似地,第二触件可被称为第一触件,这不会脱离描述的各个实施例的范围。第一触件和第二触件都是触件,但它们不是同一个触件。
在已描述的各个实施例中使用到的术语仅仅为了描述特定实施例,而不意指限制本发明。如已描述的各个实施例中使用到的,单数形式一个(“a)”、“一个(an)”和“这个(the)意在同样包括复数形式,除非上下文明确指出了其它情形。”还应当理解如本文使用的术语和“/或是指并且包括一个或多个相关联列出项目的任何和所有组合。”还应理解的是,当在本说明书中使用时,术语包括摂特指存在所陈述的特征、整体、步骤、操作、元件和/或部件,但并不排除存在或附加一个或多个其它特征、整体、步骤、操作、元件、部件和/或它们的组合。
如本文所用,取决于上下文,术语“如果”可选地被解释为表示何时或在“......上”或“响应于决定”或“响应于检测。”类似地,取决于上下文,短语“如果决定”或“如果检测到[已述的条件或事件]”可选地被解释为表示“在决定......时”或“响应于决定”或“在检测到[所述条件或事件]时”或“响应于检测到[所述的条件或事件]。”
另外,虽然本文可使用条例或方向的术语,但这些元件不应受这些术语的限制。除非另有说明,否则所有条例或取向用于区分一个元件与另一个元件的目的,并且除非另有说明,否则不表示任何特定顺序、操作顺序、方向或取向。

Claims (18)

1.一种电连接器组件,包括:
电端子,所述电端子具有沿纵向轴线延伸的附接端和沿横向轴线延伸的连接端,所述附接端构造成附接到线材线缆,所述连接端构造成附接到对应的配合端子;
第一端子外壳,所述第一端子外壳具有沿所述纵向轴线延伸的第一腔体,其中设置有所述附接端,所述第一腔体限定了供所述线材线缆延伸穿过的线缆开口,并且限定了供所述连接端延伸穿过的端子延伸开口;以及
第二端子外壳,所述第二端子外壳具有沿所述横向轴线延伸的第二腔体,其中设置有所述连接端,所述第二腔体限定了供所述连接端穿过而被接纳的端子接纳开口和构造成接纳所述对应的配合端子的配合开口,其中所述第一端子外壳限定了围绕所述端子延伸开口的第一附接表面,并且所述第二端子外壳限定了围绕所述端子接纳开口的第二附接表面,其中所述第一附接表面被密封到所述第二附接表面,并且其中所述第一附接表面相对于所述纵向轴线形成第一角度,且所述第二附接表面相对于所述横向轴线形成第二角度。
2.根据权利要求1所述的电连接器组件,其特征在于所述第二角度与所述第一角度互补。
3.根据权利要求1所述的电连接器组件,其特征在于所述第一角度的第一角度值为约45度,所述第二角度的第二角度值为约45度。
4.根据权利要求1所述的电连接器组件,其特征在于所述第一附接表面限定了围绕所述端子延伸开口的周向脊,并且所述第二附接表面限定了围绕所述端子接纳开口的周向沟槽,其中接纳有所述周向脊。
5.根据权利要求4所述的电连接器组件,其特征在于使用红外激光焊接工艺将所述周向脊焊接到所述周向沟槽。
6.根据权利要求1所述的电连接器组件,其特征在于所述第一附接表面焊接到所述第二附接表面,由此在所述第一端子外壳与所述第二端子外壳之间形成防水的接合部。
7.根据权利要求1所述的电连接器组件,其特征在于使用激光焊接工艺将所述第一附接表面焊接到所述第二附接表面。
8.根据权利要求1所述的电连接器组件,其特征在于所述第一端子外壳由第一材料形成,所述第二端子外壳由不同于所述第一端子外壳的第二材料形成。
9.根据权利要求8所述的电连接器组件,其特征在于所述第一材料是红外线穿透的,且所述第二种材料是红外线吸收的。
10.根据权利要求1所述的电连接器组件,其特征在于所述附接端的纵向轴线基本上垂直于所述连接端的横向轴线。
11.一种制造电连接器组件的方法,包括以下步骤:
提供电端子,所述电端子具有沿纵向轴线延伸的附接端和沿横向轴线延伸的连接端,所述附接端构造成附接到线材线缆,所述连接端构造成附接到对应的配合端子;
提供第一端子外壳,所述第一端子外壳具有沿所述纵向轴线延伸的第一腔体,其中设置有所述附接端,所述第一腔体限定了供所述线材线缆延伸穿过的线缆开口,并且限定了供所述连接端延伸穿过的端子延伸开口;
提供第二端子外壳,所述第二端子外壳具有沿所述横向轴线延伸的第二腔体,其中设置有所述附接端,所述第二腔体限定了供所述连接端穿过而被接纳的端子接纳开口和构造成接纳所述对应的配合端子的配合开口,其中所述第一端子外壳限定了围绕所述端子延伸开口的第一附接表面,并且所述第二端子外壳限定了围绕所述端子接纳开口的第二附接表面;
将所述电端子的附接端插设在所述第一端子外壳的第一腔体内;
将所述电端子的连接端插设在所述第二端子外壳的第二腔体内;以及
将所述第一附接表面密封到所述第二附接表面。
12.根据权利要求11所述的方法,其特征在于所述第一附接表面限定了围绕所述端子延伸开口的周向脊,并且所述第二附接表面限定了围绕所述端子接纳开口的周向沟槽,并且其中,所述方法还包括将所述周向脊设置在所述周向沟槽内的步骤。
13.根据权利要求12所述的方法,其特征在于通过使用红外激光焊接工艺将所述周向脊焊接到所述周向沟槽来执行将所述第一附接表面密封到所述第二附接表面的步骤。
14.根据权利要求11所述的方法,其特征在于通过将所述第一附接表面焊接到所述第二附接表面来执行将所述第一附接表面密封到所述第二附接表面的步骤。
15.根据权利要求11所述的方法,其特征在于使用激光焊接工艺来执行将所述第一附接表面密封到所述第二附接表面的步骤。
16.根据权利要求11所述的方法,其特征在于所述第一端子外壳由第一材料形成,所述第二端子外壳由不同于所述第一端子外壳的第二材料形成。
17.根据权利要求16所述的方法,其特征在于所述第一材料是红外线穿透的,且所述第二种材料是红外线吸收的。
18.根据权利要求11所述的方法,其特征在于所述附接端的纵向轴线基本上垂直于所述连接端的横向轴线。
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