CN110998987B - 屏蔽式电连接器组件及其制造方法 - Google Patents

屏蔽式电连接器组件及其制造方法 Download PDF

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CN110998987B
CN110998987B CN201880050290.7A CN201880050290A CN110998987B CN 110998987 B CN110998987 B CN 110998987B CN 201880050290 A CN201880050290 A CN 201880050290A CN 110998987 B CN110998987 B CN 110998987B
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shield
sheet
main wall
opening
electrical connector
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CN110998987A (zh
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W·C·洛维茨
P·J·里迪
G·E·罗宾森
M·L·梅洛特
J·A·杰尼斯
B·D·泰勒
S·P·拉加尔伊
C·D·汉顿
H·路易
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Delphi Technologies Inc
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    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
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    • H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
    • H01R13/187—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with spring member in the socket
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Abstract

屏蔽式电连接器组件(100)包括由单个导电材料的片材(120)一体地形成的电磁屏蔽件(116)。屏蔽件(116)具有主壁(122)和围绕主壁(122)的四个侧壁(124)。屏蔽件(116)限定了与主壁(122)相对的开口(126)，该开口(126)的开口周长大于或等于主壁周长。四个侧壁(128)中的一个限定了至少一个侧壁开口(130)，该侧壁开口被构造成接纳屏蔽线材线缆。一种制造屏蔽式电连接器组件(100)的方法(400)包括以下步骤：提供单个平面的导电材料的片材(120)，提供模具(344)和冲头(346)，使用模具(344)和冲头(346)将片材(120)形成为具有主壁(122)和围绕主壁(122)的四个侧壁(124)的杯形，以及在四个侧壁(128)中的一个中形成侧壁开口(130)。

Description

屏蔽式电连接器组件及其制造方法
相关申请的交叉引用
本申请要求申请日为2017年8月1日的美国临时专利申请第62/539,656号的专利合作条约第8条的权益，其全部公开内容通过引用合并于此。
技术领域
本发明涉及一种电连接器组件，特别涉及一种能够承载超过200安培的电流的屏蔽式电连接器组件，以及一种制造这种电连接器组件的方法。
附图说明
现在将参考附图通过示例描述本发明，附图中：
图1是根据本发明的实施例的屏蔽式电连接器组件的立体图；
图2是根据本发明的实施例的包括电磁屏蔽件的图1的屏蔽式电连接器组件的分解立体图；
图3是根据本发明的实施例的图2的预成型的电磁屏蔽件的立体图；
图4是根据本发明的实施例的图3的形成的电磁屏蔽件的立体图；
图5是根据本发明的实施例的图1的屏蔽式电连接器组件的替代电磁屏蔽件的立体图；
图6是根据本发明的实施例的替代的屏蔽式电连接器组件的立体图；
图7是根据本发明的实施例的替代的预成型电磁屏蔽件的分离立体图；
图8是根据本发明的实施例的处于中间形成步骤中的图7的电磁屏蔽件的分离立体图；
图9是根据本发明的实施例的成形之后的图7的电磁屏蔽件的分离立体图；以及
图10是根据本发明的实施例的制造屏蔽式电连接器组件的方法的流程图。
具体实施方式
现在将详细参考实施例，这些实施例的示例在附图中示出。在以下详细说明中，阐述了许多具体细节以便提供对各种描述的实施例的透彻理解。然而，对于本领域普通技术人员显而易见的是，可以在没有这些具体细节的情况下实践各种描述的实施例。在其它情况下，没有详细描述众所周知的方法、过程、部件、电路以及网络，以免不必要地模糊实施例的各方面。
本文提出的是一种密封的电连接器组件，其适合于坚固、可靠且安全地承载大于200安培的电流。
图1示出了在下文中称为组件100的屏蔽式电连接器组件的实施例，其包括具有阴连接器壳体或主体104的阴连接器102，阴连接器主体104包含连接至一对屏蔽线材线缆106的一对插座端子(未示出)。组件100还包括具有阳连接器壳体或主体110阳连接器108，阳连接器主体110包含与阴连接器主体104中的插座端子互连的一对片式端子112。组件100还包括连接辅助杆114。该组件100可以适合于高功率电连接，诸如在电动车辆动力系中所需的那些。阴连接器主体和阳连接器主体104、110由诸如工程聚合物之类的电绝缘材料、即电介质材料形成。插座端子和片式端子112由诸如铜合金之类的导电材料形成。屏蔽线缆各自具有由聚合物内绝缘套支承的中心导体，诸如股线铜质线材线缆。每条线缆的内套由诸如编织的铜线套管之类的屏蔽导体围绕，该屏蔽导体被聚合物外绝缘套围绕。
如图2所示，阴连接器102包括以下称为屏蔽件116的电磁屏蔽件，屏蔽件116接纳在由阴连接器主体104限定的连接器腔体118(参见图6)内。屏蔽件116电连接到屏蔽线材线缆106的屏蔽导体，并且围绕插座端子和片式端子112之间的接口的至少一部分。在图2所示的实施例中，屏蔽件116由薄的导电箔形成，诸如厚度小于0.38毫米(约0.015英寸)的铝箔。
如图3所示，屏蔽件116由平面的箔的片材120一体地形成，该片材被切割(例如冲切)成期望的形状，使得在片材120成形之后，屏蔽件116的特征在于具有如图4所示的主壁122和围绕主壁122的四个侧壁124。屏蔽件116限定了与主壁122相对的开口126，该开口126的开口周长大于或等于主壁周长。四个侧壁124中的一个(例如前侧壁128)限定了一对侧壁开口130，该一对侧壁开口130构造成接纳一对屏蔽线材线缆106。可以使用模具和冲头将箔的片材120成形为屏蔽件116的形状。与现有技术的屏蔽件相比，薄的箔屏蔽件116提供了成本较低的工具和成型工艺较为容易的优点，现有技术的屏蔽件由较厚的金属片材制成，且需要渐进模具以获得所期望的形状。
返回图2，阴连接器102还包括在下文中称为支承件132的屏蔽件支承结构，其被接纳在由主壁122和四个侧壁124形成的屏蔽腔体134内。支承件132由诸如工程聚合物之类的电绝缘材料、即电介质材料形成。如图2所示支承件132的特征在于具有主壁和围绕主壁122的四个侧壁。支承件限定了与主壁相对的开口。支承件132的前侧壁限定了一对侧壁开口，该对侧壁开口被构造成接纳一对屏蔽线材线缆106。支承件在主壁和四个侧壁之间还限定了支承腔体，在该支承腔体中设置片式端子和插座端子接口。
支承件132增强屏蔽件116的刚度以允许操纵薄箔屏蔽件116而不使屏蔽件116变形或损坏。支承件132还提供了以下优点，即，使屏蔽件116与端子电绝缘，由此防止端子与接地屏蔽件116之间的短路。支承件132可以在形成屏蔽件116的期间与成型模具一起使用，其中支承件132用作冲头以将片材120成形为期望形状的屏蔽件116。如图4所示，屏蔽件116的侧壁124围绕开口126限定了多个凸片136，这些凸片在支承件132上折叠以将屏蔽件116固定到支承件132上。支承件132还可用于将屏蔽件116插入到连接器腔体118中。
如图5所示，屏蔽件116可包括屏蔽件延伸(延展)部138，该屏蔽件延伸部138装配在一对侧壁开口130内，以沿着连接器腔体118内的屏蔽线材线缆106提供附加的屏蔽。这些屏蔽延伸部138可以由金属片材使用较不复杂的渐进模具冲压形成。
图6示出了替代的屏蔽件构造，其中，屏蔽件216由金属片材形成，该金属片材被深拉成所需形状，且具有主壁222和围绕该主壁222的四个侧壁224，其中屏蔽件216限定了与主壁222相对的开口226，开口226的开口周长大于或等于主壁周长。屏蔽件216还包括夹持件240，该夹持件240例如通过螺纹紧固件242将屏蔽线材线缆106的屏蔽件导体固定到屏蔽件216。该屏蔽件216提供以下的优点，即消除了侧壁224之间的接缝。
图7至图9示出了又一种替代的屏蔽(件)结构，其中屏蔽件316由诸如延伸(延展)的铝之类的的延伸金属的网状或筛网状的片材320形成。使用模具344和冲头346将延伸的铝的片材320形成为期望的形状，该形状具有主壁322和围绕主壁322的四个侧壁324，其中，屏蔽件316限定了与主壁322相对的开口326，该开口的开口周长大于或等于主壁周长。从模具344中取出屏蔽件后，修整屏蔽件316，并在前侧壁328上切出一对侧壁开口330。支承件132可用于增强屏蔽件316的刚度以允许操纵屏蔽件316，而不使屏蔽件316变形或损坏。支承件132可以用作冲头346，以将延伸的铝的片材320成形为期望形状的屏蔽件316。该屏蔽件316还提供以下的益处，即消除了侧壁324之间的接缝。
图10示出了制造组件100的方法400。方法400包括以下步骤：
步骤410(提供导电材料的片材)包括提供诸如铝箔片材之类的单个平面的导电材料的片材120。
步骤412(提供模具和冲头)包括提供模具344和冲头346，模具344和冲头346构造成以将片材120形成为期望形状的屏蔽件116。
步骤414(提供限定连接器腔体的连接器壳体)包括提供限定连接器腔体118的阴连接器壳体104。
步骤416(提供屏蔽件支承结构)包括提供支承件132。
步骤418(将片材形成为具有主壁和四个侧壁的杯形)包括使用模具344和冲头346将片材120形成为具有主壁122和围绕主壁122的四个侧壁124的杯形。杯形限定了与主壁122相对的开口126，该开口126的开口周长大于或等于主壁周长。
步骤420(在四个侧壁中的一个中形成侧壁开口)包括在四个侧壁124中的一个中形成至少一个侧壁开口。
步骤422(将屏蔽件设置在连接器腔体内)包括将屏蔽件116设置在连接器腔体118内。
步骤424(将屏蔽件支承结构设置在主壁和四个侧壁形成的屏蔽腔体内)包括将支承件132设置在由主壁122和四个侧壁124形成的屏蔽腔体134内。当支承件被用作冲头346时，步骤424(将屏蔽件支承结构设置在主壁和四个侧壁形成的屏蔽腔体内)可以与步骤418(将片材形成为具有主壁和四个侧壁的杯形)同时执行。
如本文所述，提供了一种屏蔽式电连接器组件100和一种制造该屏蔽式电连接器组件100的方法400。组件100和方法400提供了降低制造成本的益处，因为可以在仅需要两个工作站的两个过程中将片材120冲切并形成为屏蔽件116。可以将更软的、成本更低的金属箔或延伸(延展)金属用于屏蔽件116，因为屏蔽件116由支承件132机械地支承，并且可以立即插入到连接器腔体118中，在连接器腔体118中保护屏蔽件116免受操作损坏。
虽然已经根据本发明的优选实施例描述了本发明，但是本发明并不旨在受限于此，而是仅受以下的权利要求书中所阐述的范围限制。例如，上述实施例(和/或其方面)可以彼此结合使用。此外，可作各种修改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”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(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。还应当理解术语“和/或”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，在本文中所使用的术语“包括”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。
在本文中所使用，术语“如果”可选地被解释为表示“当……时”或“在......时”或“响应于决定”或“响应于检测”，取决于上下文。类似地，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]，”取决于上下文。
另外，虽然在此可以使用条例或定向的术语，但是这些元件不应受这些术语的限制。除非另有说明，否则所有条例或定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，方向或定向。

Claims (10)

1.一种制造屏蔽式电连接器组件（100）的方法（400），所述方法包括以下步骤：
提供单个平面的导电材料的片材（120）；
提供模具（344）和冲头（346）；
提供屏蔽件支承结构（132）；
使用模具（344）和用作冲头（346）的所述屏蔽件支承结构（132）将片材（120）形成为具有主壁（122）和四个侧壁（124）的杯形，从而将所述屏蔽件支承结构（132）设置在由主壁（122）和四个侧壁形成的屏蔽腔体内，所述杯形限定了与所述主壁（122）相对的开口（126），所述开口（126）的开口周长大于或等于主壁周长；以及
在四个所述侧壁中的一个中形成（420）侧壁开口（130）。
2.根据权利要求1所述的方法（400），其特征在于，平面的所述片材（120）是厚度小于0.38毫米的金属箔。
3.根据权利要求1所述的方法（400），其特征在于，平面的所述片材（120）由延伸金属片材形成。
4.根据权利要求3所述的方法（400），其特征在于，平面的所述片材（120）由延伸的铝的片材（320）形成。
5.根据权利要求1至4中任一项所述的方法（400），其特征在于
还包括以下步骤：
提供限定了连接器腔体（118）的连接器壳体（104）；以及
将由所述片材形成的杯形的屏蔽件（116）设置在所述连接器腔体（118）内。
6.一种通过工艺（400）制造的屏蔽式电连接器组件（100），所述工艺（400）包括以下步骤：
提供单个平面的导电材料的片材（120）；
提供模具（344）和冲头（346）；
提供屏蔽件支承结构（132）；
使用模具（344）和用作冲头（346）的所述屏蔽件支承结构（132）将片材（120）形成为具有主壁（122）和四个侧壁（124）的杯形，从而将所述屏蔽件支承结构（132）设置在由所述主壁（122）和所述四个侧壁形成的屏蔽腔体内，所述杯形限定了与所述主壁（122）相对的开口（126），所述开口（126）的开口周长大于或等于主壁周长；以及
在四个所述侧壁中的一个中形成（420）侧壁开口（130）。
7.根据权利要求6所述的屏蔽式电连接器组件（100），其特征在于，所述工艺（400）还包括以下步骤：
提供限定了连接器腔体（118）的连接器壳体（104）；以及
将由所述片材形成的杯形的屏蔽件（116）设置（422）在所述连接器腔体（118）内。
8.根据权利要求6或7所述的屏蔽式电连接器组件（100），其特征在于，平面的所述片材（120）是厚度小于0.38毫米的金属箔。
9.如权利要求6所述的屏蔽式电连接器组件（100），其特征在于，平面的所述片材（120）由延伸金属片材形成。
10.如权利要求9所述的屏蔽式电连接器组件（100），其特征在于，平面的所述片材（120）由延伸的铝片材（320）形成。
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