DE102006010037A1 - Assembly method for manufacturing of electrical coaxial connector subassembly, involves inserting outer conductor casing of electrical coaxial connector subassembly in forming tool of injection molding machine in method step - Google Patents

Abstract

The method involves inserting an outer conductor casing (110) of the electrical coaxial connector subassembly (1,1a) in a forming tool of an injection molding machine in a method step. A housing (100) of plastic is extruded at the outer conductor casing in another method step. Engagement hook (102a), Contact-dielectric (104), : Independent claims are also included for the following: (1) an electrical coaxial connector subassembly for use in motor vehicle field (2) an electrical coaxial plug or electrical coaxial socket for use in motor vehicle field.

Description

The The invention relates to a mounting method for producing a complete electrical Coaxial Connector Subassembly (Coaxial Connector or Coaxial Coupler Subassembly) and a corresponding coaxial connector electrical subassembly, in particular for the The automotive sector.

coaxial form z. B. in analog image transmission or digital communication in computer networks the prevailing Wiring type, as compared to conventional cables, essential less vulnerable across from Are disturbing influences and transport much more data. Especially in the automotive sector Coaxial cable increasingly used to z. B. an electrical connection of the electrical system with a radio, a GPS device or mobile radio devices manufacture. Further find coaxial cable and coaxial connectors a broad field of application in telecommunications where they for different ones Connections used in the base stations of mobile communication networks become.

coaxial or coaxial connectors are used for electrical coupling of Coaxial cables or to connect a coaxial cable to an electrical or electronic component or assembly. A coaxial cable includes essentially two concentric conductors (inner and outer conductors), which are electrically isolated from each other by a dielectric. In a coaxial connector is an inner conductor contact the Plug connection with the inner conductor of the coaxial cable electrically connected and represents the extension the signal transmission path The coaxial connector also has an outer conductor contact on, who with the Kabelaußenlei ter, usually a wire mesh of copper, is electrically connected and represents a connection to the ground path.

The DE 203 02 072 U1 discloses a coaxial electrical connector having a coaxial electrical connector and a coaxial electrical connector, also called a coaxial connector. The coupler and the plug each have a stepped tube, which is electrically connected to an outer conductor of a coaxial cable. The tube is received in each case in a corresponding plug or coupler housing and fixed by means of a fitting and corresponding locking means in the respective housing. Also located within the stepped tube functioning as the outer contact spring is an insulating member which receives an inner conductor pin contact on the plug and an inner conductor socket contact on the coupler, the pin contact or the socket contact being electrically connectable to the inner conductor of the coaxial cable.

Such electrical coaxial connectors (coaxial connectors or coaxial couplers or coaxial sockets) each have a plurality of individual parts on, whereby an assembly of the connector is correspondingly expensive. As a result, an assembly or assembly of the connector or a Subassembly thereof comparatively expensive. Furthermore is also the multitude of different individual components of each Connector in the sum comparatively expensive.

So is for each coaxial connector subassembly (the subassembly is missing the respective inner conductor pin contact or inner conductor socket contact) a separate housing, a separate external contact spring, an own fitting piece and a separate insulating part provided, wherein for the respective fitting piece an additional, not on the case trained locking means for position finding is necessary. Thus, coaxial connector subassemblies are known in the art five each Components built up; d. H. For a complete Coaxial connector subassembly consisting of a coaxial connector subassembly and a coaxial coupler subassembly Ten different components are necessary.

It It is an object of the invention to provide an improved coaxial connector subassembly (Coaxial Subassembly or Coaxial Coupler Subassembly) to disposal to deliver. In particular, while the assembly costs of the respective Subassembly be reduced to allow a cost-effective production. Therefor should the connector subassembly have few components, so that the assembly process can be carried out quickly and further should consider the individual components for a subassembly in the Sum should not be too costly.

The The object of the invention is achieved by an assembly method for manufacturing a coaxial electrical connector subassembly, wherein to an outer conductor sleeve of Subassembly a plastic housing is injected. Furthermore, the invention is characterized by an electrical Coaxial connector subassembly solved, at the outer conductor sleeve casing is poured. Here, the housing is the coaxial connector subassembly firmly connected to the outer conductor sleeve. For the Making the coaxial connector subassembly is an injection molding process, wherein the outer conductor sleeve in a Mold of a suitable injection molding machine is used.

According to the invention, conventional assemblage steps are eliminated and are introduced by inserting the outer conductor sleeve into the mold of the Injection molding machine and a subsequent injection of the housing to the outer conductor sleeve replaced. As a result, a coaxial connector electrical subassembly is rationally obtained by eliminating a variety of assembling steps and components for the subassembly. According to the outer conductor sleeves are molded with plastic only. The respective insulating parts or contact dielectrics with the corresponding inner conductor contact can then be plugged into the outer conductor sleeve into the subassembly according to the invention.

In a preferred embodiment However, the invention will be the corresponding contact dielectric while of the injection molding with poured into the outer conductor sleeve. hereby you get according to the invention in two Procedural steps (inserting the outer conductor sleeve in the mold and the subsequent injection molding process) a complete electrical Coaxial connector subassembly immediately after removal the injection molding machine by means of an inner conductor contact to the finished electric coaxial coupler or the finished coaxial electrical connector vervollständigbar is. In the prior art, for a single complete coaxial connector subassembly, there are five different ones Items and the assemblage steps needed to do that according to the invention essential can be done easier.

The to be poured into the subassembly or to be injected contact dielectric can be made of the same Plastic material made as the housing be. In another embodiment of the Invention consist of the housing and the contact dielectric of different plastic materials, wherein as a manufacturing method preferably a 2K injection molding method is used.

According to the invention casing while of the injection molding process designed such that it individual or all later required Features such. B. a latching hook or a corresponding thereto Bow and / or Coding recesses or coding projections corresponding thereto and / or a corresponding release device for the Hanger. This ensures that the housing or the subassembly nach the removal from the injection mold their intended suitability has, without a reworking is absolutely necessary.

In a preferred embodiment the invention is the outer conductor sleeve in one Area in which they do not have electrical contacting tasks with the coaxial cable or an outer conductor sleeve of another connector, with projections, Holes, nubs, beads or the like provided, whereby the outer conductor sleeve later fixed in sitting on the outer conductor sleeve to spritzendem housing. Preference is given to a running around the outer conductor sleeve bead or Wandungsfalz intended.

Further the invention relates to a coaxial electrical connector or a electric coaxial coupler for the motor vehicle area, with an electrical according to the invention Coaxial subassembly. The electrical coaxial connector has an inner conductor pin contact and the electrical coaxial coupler an inner conductor socket contact.

By the inventive method receives You can save costs in logistics and assemblage, because only one single prefabricated part (possibly a two-piece) for a single connector is needed; the rest is poured essentially according to the invention. Further will be for the Assembling fewer tools than previously needed, since a finished part made the tool comes.

Further embodiments The invention results from the remaining dependent claims.

The Invention will now be described with reference to exemplary embodiments with reference on the attached Drawing closer explained. In the drawing show:

1 a three-dimensional view of a coaxial connector subassembly according to the invention;

2 a three-dimensional representation of a coaxial coupler subassembly according to the invention;

3a the coaxial connector subassembly of the 1 in a front view;

3b a side view of the connector subassembly

3a along a line AA in the 3a ;

4a the coaxial coupler subassembly of 2 in a front view;

4b a side view of the coupler subassembly from 4a along a line BB in the 4a

5 an inner conductor pin contact for the electrical coaxial connector subassembly according to the invention;

6 an inner conductor socket contact for the coaxial coupler subassembly according to the invention;

7 the inner conductor socket contact 6 with a crimped inner conductor of a coaxial cable; and

8th a sectional side view of a second embodiment of the plug subassembly.

The following versions relate to an electrical Koaxialstecker- and an electrical Coaxial coupler subassembly or a corresponding coaxial connector and a corresponding coaxial coupler. The plug and the coupler or their respective subassemblies have a similar structure and an identical manufacturing process, so that the statements of the coupler also refer to the plug and vice versa. The same thing especially applies to the respective subassemblies. Where differences arise will be noted separately. Beyond that - to misunderstandings to prevent - the Coaxial coupler and the coaxial connector under the generic coaxial connector summarized. So it is under a coaxial connector both a coaxial connector as well as a coaxial coupler understood. The same applies to the corresponding subassemblies.

The 1 and 2 each show a coaxial electrical connector subassembly, wherein 1 an electrical coaxial connector subassembly 1a and the 2 an electrical coaxial coupler subassembly 1b shows. In the following, the index a relates to the connector and the index b to the coupler. The respective subassembly represents a divisible unit into which a corresponding inner conductor contact 2 (S. 5 to 7 ) is insertable from the rear, so that a preferably complete coaxial connector with inner conductor pin contact 200a (S. 5 ) and a preferably complete coaxial coupler having an inner conductor female contact 200b (S. 6 ) arises. This so-called packaging is preferably carried out by a customer who configures the plug or the coupler individually.

The respective coaxial connector electrical subassembly 1 has a housing 100 or a surrounding housing 100 with a locking element 102 (Latching hooks 102 , Hanger 102b ) and inside in a cavity of the housing 100 an outer conductor sleeve 110 on, which electrically with an outer conductor 310 (S. 7 ) of a coaxial cable 3 is connectable.

The housing 100 the electrical coaxial connector subassembly 1a (S. 1a ) essentially has a box-shaped main body and one of them projecting in an axial direction A hollow cylindrical portion. The hollow cylindrical and the box-shaped portion are in this case materially formed integrally with each other. On a circumference of the hollow cylindrical portion is located outside a latching hook 102 by means of which the plug subassembly 1a in a coaxial coupler subassembly 1b is latched. Here, the hollow cylindrical portion of the plug subassembly becomes 1a in a front hollow section of the housing 100 the coupler subassembly 1b plugged in. In the locked state of connector 1a and coupler subassembly 1b locks the latching hook 2a with one on the housing of the coupler subassembly 1b trained temple 102b ,

The housing 100 the coaxial coupler electrical subassembly 1b (S. 1b ) is also substantially box-shaped and has at the top of the bracket 102b and a release device 103b for the temple 102b on. To release the release device 103b towards the case 100 the coupler subassembly 1b pressed, causing the hanger 102b from the case 100 moved away and the latch hook 102 the plug subassembly 1a can release. The housing 100 the coupler subassembly 1b is a front portion formed as a hollow cylinder and from the front for the hollow cylindrical portion of the coaxial connector subassembly 1a accessible.

At its inner hollow cylinder circumference, the coupler subassembly 1b in an axial direction A of the subassembly 1b extending Codierausnehmungen 106 into which corresponding Kodiervorsprünge the plug subassembly 1a can intervene. These serve to ensure that only the coaxial connectors can be plugged into associated coaxial couplers. The coding tabs on the connector subassembly 1a are not shown in the drawing and - if present - outside the circumference extending in the axial direction A formed as a projection. There may be any number of Kodierausnehmungen 106 and corresponding coding projections, it being also possible to use the coding projections on the coupler subassembly 1b - z. B. inside of the hollow cylindrical portion - and the Kodierausnehmungen 106 on the plug subassembly 1a - z. B. outside of the hollow cylindrical portion - provide.

Furthermore, the housing has 100 the coupler subassembly 1b an elongated, slot-shaped recess 105b in a housing wall, along which the latching hook 102 the plug subassembly 1a when plugged into the coupler subassembly 1b can slide along to the bracket located further out 102b to be able to lock. It should be noted that latching hook 102 and hangers 102b among themselves can be reversed. Ie. Alternatively, the bracket 102b on the plug subassembly 1a and the latching hook 102 at the coupler subassembly 1b be provided.

The 3a and 3b show two views of the coaxial connector subassembly 1a , where the 3a a front view and the 3b a sectional side view along in 3a Plotted AA level.

In particular in 3b you can see that the outer conductor sleeve 110 in the molded, preferably injection molded, housing 100 is included. The outer conductor sleeve 110 is a substantially one-piece, tubular part, with a rear of the housing 100 protruding portion preferably has a slightly smaller diameter than that inside the housing 100 recorded section. These two sections of the outer conductor sleeve 110 are provided integrally over an overlapping fold to each other. The fold forms one as a bead 116 trained lead 116 , This preferably completely circumferential projection 116 guarantees a firm and secure hold of the outer conductor sleeve 110 in the case 100 , Furthermore, it is located inside the outer conductor sleeve 110 a contact dielectric 104 , which in that section of the outer conductor sleeve 110 is included within the housing 100 lies. The contact dielectric 104 extends preferably to a free end of the outer conductor sleeve 110 which is inside the case 100 is provided. The contact dielectric 104 has a stepped bore into which the inner conductor pin contact 200a (S. 5 ) - but with it crimped coaxial cable - can be used. The front section of the contact dielectric 104 is configured such that a contact dielectric 104 the coupler subassembly 1b is partially absorbable.

A principle of the same construction, the electrical coaxial coupler subassembly 1b on that in the 4a and 4b is shown, wherein 4a a front view and 4b a sectional side view along in 4a drawn plane BB is shown.

In essence, the case 100 the coupler subassembly 1b configured such that a front free end of the housing 100 the plug subassembly 1a in the case 100 the coupler subassembly 1b is pluggable with little play. When inserted, the outer conductor sleeve contacts 110 the coupler subassembly 1b the outer conductor sleeve 110 the plug subassembly 1a electric. So that the outer conductor sleeve 110 the plug subassembly 1a the outer conductor sleeve 110 the coupler subassembly 1b can electrically contact, has the outer conductor sleeve 110 the coupler subassembly 1b a contact spring 114 on, which on the outer conductor sleeve 110 is attached. This locks the contact spring 114 with the outer conductor sleeve 110 at mutually corresponding recesses and locking projections. In this case, preference is given to a free (housing-internal) end section of the outer conductor sleeve 110 embossed an annular recess into which a within the contact spring 114 provided annular bead engages. As a result, contact spring 114 and outer conductor sleeve 110 firmly connected. Otherwise, the respective outer conductor sleeves 110 The plug- 1a and the coupler subassembly 1b preferably identically constructed, so that from an outer conductor sleeve 110 the plug subassembly 1a an outer conductor sleeve 110 the coupler subassembly 1b can be produced. However, it is also possible the contact spring 114 and the outer conductor sleeve 110 as an integral part.

That inside the case 110 lying free end of the outer conductor sleeve 110 the plug subassembly 1a can be with some force from the free end of the contact spring 114 coming into the contact spring 114 plug in. Here, the con tact spring expands 114 , due to provided in their wall slots, something on, so that a secure electrical connection between the contact spring 114 and outer conductor sleeve 110 the coaxial connector subassembly 1a is realized. D. h., An inner diameter of the contact spring 114 is slightly smaller than an outer diameter of the free end of the outer conductor sleeve 110 the plug subassembly 1a ,

Furthermore, it is located in a housing 100 inner section of the outer conductor sleeve 110 the coupler subassembly 1b also a contact dielectric 104 (Sao), which preferably forward of the inner conductor sleeve 110 in the case 100 protrudes. This extension is preferably completely from the contact spring 114 surround. The outer diameter of the extension is slightly smaller than the inner diameter of the contact dielectric 104 the plug subassembly 1a in a front area. In addition, the outer conductor sleeve 110 the coupler subassembly 1b also a fold or a preferably completely circumferential bead-shaped projection 116 on, by means of which the outer conductor sleeve 110 firmly in the housing 100 sitting.

According to the invention, the respective housing 100 to the outer conductor sleeve 110 molded. Here, the outer conductor sleeve 110 or the outer conductor sleeve 110 together with the contact spring fixed on it 114 - In the following also only as outer conductor sleeve 110 designated - used in a mold of an injection molding machine and then the housing 100 to the outer line terhülse 110 molded. In this case, the respective contact dielectric 104 also within the outer conductor sleeve 110 be provided. Here, contact dielectric 104 and housing 100 be made of the same plastic material or different materials. In the latter case, a 2K plastic injection molding process is preferred. According to the invention can in two steps (inserting the outer conductor sleeve 110 in the mold and subsequent encapsulation of the outer conductor sleeve 110 ) a preferably complete, ready-to-ship subassembly 1a . 1b getting produced.

Should be a direct potting of the contact dielectric 104 during the manufacture of the subassembly 1a . 1b not possible, so it is possible before inserting the outer conductor sleeve 110 in the mold, the contact dielectric 104 in the outer conductor sleeve 110 provide or the contact dielectric 104 after the plastic injection molding process in the outer conductor sleeve 110 provided. In the latter embodiment, it is possible to use the contact dielectric 104 together with the respective inner conductor contact 2 in the outer conductor sleeve 110 provided.

Through the bead 116 on the outer conductor sleeve 110 is the outer conductor sleeve 110 fixed in the axial direction A in the housing 100 intended. In a direction perpendicular to the outer conductor sleeve 110 through a wall of the housing 100 held, so that the outer conductor sleeve 110 with respect to the housing 100 can not move.

Further, in the coupler subassembly 1b a free end of the contact spring 114 also preferably within the wall of the housing 100 intended. Ie. during encapsulation of the outer conductor sleeve 110 becomes the plug end of the contact spring 114 opposite end into the housing 100 cast. Advantageously, this end has outwardly bent end portions, so that by an undercut the contact spring 114 additionally in the housing 100 is held. This is with the position 113 in 4b marked.

The 3b and 4b provide with or without the appropriate contact dielectric 104 So-called subassemblies (subassemblies), which are delivered in this form to a customer. The customer then populates these subassemblies with one to an inner conductor contact 2 crimped coaxial cable, which has different lengths depending on the application.

Such inner conductor contacts 2 are in the 5 and 6 shown, these still on a carrier 210 hang before connecting to a coaxial cable 3 (S. 7 ) is removed.

This shows 5 the inner conductor pin contact 200a and 6 the inner conductor socket contact 200b , Preferably, the inner conductor pin contact 200a in the outer conductor sleeve 110 the plug subassembly 1a and the inner conductor socket contact 200b preferably in the outer conductor sleeve 110 the coupler subassembly 1b plugged in or attached. However, it is also possible, the inner conductor pin contact 200a with the inner conductor socket contact 200b to swap.

7 shows one to an inner conductor 320 of the coaxial cable 3 mounted inner conductor socket contact 200b , Here, the gradually stripped coaxial cable 3 with its inner conductor 320 to a crimping area of the inner conductor socket contact 200b crimped. Subsequently, this subassembly is backward in the outer conductor sleeve 110 the coupler subassembly 1b plugged in (from the right in the 4b ). This is the socket contact 200b that far into the coupler subassembly 1b plugged in until the stop of the socket contact 200b inside in the housing 100 at the contact dielectric 104 abuts. This locks the socket contact 200b within the outer conductor sleeve 100 , When advancing the socket contact 200b in the outer conductor sleeve 110 is the outer conductor preferably consisting of an expanded mesh 310 outside on the outer conductor sleeve 110 placed. Subsequently, a crimp barrel 4 to the housing 100 over the outer conductor 310 and the underlying outer conductor sleeve 110 pushed and to the rear end of the outer conductor sleeve 110 firmly crimped. This results in an electrical coaxial coupler according to the invention.

Analog will be with a plug subassembly 1a and one with a coaxial cable 3 crimped inner conductor pin contact 200a method.

The present inner conductor contacts 2 are preferably punched out of a metal sheet. However, it can also rotated inner conductor contacts 2 be used.

Further, it is possible for both the plug subassembly 1a as well as coupler subassembly 1b the outer conductor sleeve 110 by means of through holes 117 (S. 8th ) or passage slots (not shown in the drawing) in the outer conductor sleeve 110 rotationally fixed, with housing material within these holes 117 is included. This can be done in addition to or in addition to folding 116 be provided.

When in the 8th illustrated plug subassembly 1a are the contact dielectric 104 and the case 100 made of the same material. However, it is also a 2K injection molding method applicable, in which the Dielekt rikum 104 and the case 100 made of different plastic materials. In such embodiments, liquid plastic runs into the holes 117 and put the outer conductor sleeve 110 later in the solidified housing 100 firmly. The holes are preferred 117 round; However, they can also any other form, such as. B. a rectangular. Shape, own.

In addition, the outer conductor sleeve 110 in all embodiments of the invention have a stage.

a

index for plug

b

index for couplers (Rifle)

1

electrical Coaxial subassembly

1a

(Coaxial) connector subassembly, subassembly

1b

(Coaxial) coupler subassembly, subassembly

100

Housing, housing

102

locking element

102

Locking hooks; alternatively ironing

102b

Hanger; alternative latch hook

103b

release device

104

Contact dielectric

105b

recess

106

coding aperture preferably at the coupler b

110

Outer conductor sleeve or outer conductor sleeve with contact spring 114

112

Sleeve base body

113

Head Start, undercut

114

contact spring

116

Head Start, Bead, fold

117

Through hole hole

2

Inner conductor contact

200a

Inner conductor pin contact

200b

Inner conductor socket contact

210

carrier

220

attack

3

coaxial

310

Outer conductor, braid of the coaxial cable 3

320

Inner conductor of the coaxial cable 3

330

Coaxial dielectric

340

Outer jacket of the coaxial cable 3

4

crimp barrel

A

Axial direction (s) of the outer conductor sleeve 10 or the coaxial connector electrical subassembly 1

Claims (11)

Assembly method for manufacturing a coaxial connector electrical subassembly ( 1 ; 1a . 1b ), wherein in a first method step, an outer conductor sleeve ( 110 ) of the coaxial connector electrical subassembly ( 1 ; 1a . 1b ) is used in a mold of an injection molding machine, and in a second process step, a housing ( 100 ) made of plastic to the outer conductor sleeve ( 110 ) is injected. Assembly method according to claim 1, wherein preferably during the second method step or in a preceding or subsequent sub-method step in the outer conductor sleeve ( 110 ) a contact dielectric ( 104 ) is poured. Mounting method according to claim 1 or 2, wherein the housing ( 100 ) and the contact dielectric ( 104 ) are made of the same plastic material. Mounting method according to claim 1 or 2, wherein the housing ( 100 ) and the contact dielectric ( 104 ) are made of different plastic materials, preferably with a 2k injection molding process. Mounting method according to one of claims 1 to 4, wherein in the manufacture of the housing ( 100 ) a latching element ( 102 ; 102 . 102b ) on the housing ( 100 ) is formed, the material integral with the housing ( 100 ) is formed. Electric coaxial connector subassembly, in particular for the motor vehicle sector, with a housing ( 100 ) and one in the housing ( 100 ) outer conductor sleeve ( 110 ) with an outer conductor ( 310 ) of a coaxial cable ( 3 ) is electrically connectable, wherein the housing ( 100 ) of the coaxial connector electrical subassembly ( 1 ; 1a . 1b ) to the outer conductor sleeve ( 110 ) and thereby the housing ( 100 ) fixed to the outer conductor sleeve ( 110 ) connected is. A coaxial connector electrical subassembly according to claim 6, wherein the outer conductor sleeve ( 110 ) internally a molded contact dielectric ( 104 ), preferably directly in the manufacture of the housing ( 100 ) in the outer conductor sleeve ( 110 ) is introduced. A coaxial connector electrical subassembly according to claim 6 or 7, wherein the housing ( 100 ) and the contact dielectric ( 104 ) are made of the same plastic material. A coaxial connector electrical subassembly according to any one of claims 5 to 6, wherein the housing ( 100 ) a latching element ( 102 ; 102 . 102b ), the material integral with the housing ( 100 ) is formed and directly in the production of Ge housing ( 100 ) on the housing ( 100 ) is formed. A coaxial connector electrical subassembly according to any one of claims 6 to 9, wherein the outer conductor sleeve ( 110 ) in a middle section a projection ( 116 ), which the outer conductor sleeve ( 110 ) firmly in the encapsulated housing ( 100 ), the projection ( 116 ) preferably as a completely circumferential bead ( 116 ) is trained. An electrical coaxial or automotive coaxial jack, comprising a coaxial connector electrical subassembly ( 1 ; 1a . 1b ) according to one of claims 1 to 10, wherein the coaxial electrical connector (index a) has an inner conductor pin contact ( 220a ) or the electrical coaxial socket (index b) an inner conductor socket contact ( 220b ) having.