EP4645611A1

EP4645611A1 - Metal shell for a connector for connecting two electrical components

Info

Publication number: EP4645611A1
Application number: EP24173090.2A
Authority: EP
Inventors: Matthew Steven Houser; Marc Reinhardt; Felix Schneider; Christian Rusch; Alexander J. ANTHONY
Original assignee: TE Connectivity Solutions GmbH
Current assignee: TE Connectivity Solutions GmbH
Priority date: 2024-04-29
Filing date: 2024-04-29
Publication date: 2025-11-05
Also published as: WO2025228881A1

Abstract

The present invention is directed to an metal shell (2) for a connector (1) for connecting two electrical components, said metal shell (2) being adapted to be connected at one end (2a) to a first electrical component and at the other end (2b) to a second electrical component, wherein the metal shell (2) is a metal tube (10) which is curved along its longitudinal direction. The present invention is also directed to manufacturing methods for manufacturing a connector (1) connecting two electrical components. With such a metal shell (2) for a connector (1) for connecting two electrical components and with such manufacturing methods, the present invention makes it possible to overcome the disadvantages of existing connector designs in terms of high cost, material waste, and non-optimized RF performance due to the use of multi-piece zinc die-cast housings for creating the respective data channel.

Description

The present invention relates to a metal shell for a connector for connecting two electrical components, and to a method of manufacturing a connector for connecting two electrical components.
A metal shell for a connector, used to connect two electrical components, is well-known. It provides mechanical support and protection for the internal electrical connections and ensures proper alignment and mating of the components. The connector shell is usually a die-cast housing and serves as a shield, protecting the electrical connections from environmental factors such as moisture, dust, and electromagnetic interference.
Connector shells are available in various shapes, sizes, and materials, depending on the specific application requirements. Common materials used for connector shells include aluminum, stainless steel, brass, and zinc die-cast. The choice of material depends on factors such as the desired level of mechanical strength, electrical conductivity, corrosion resistance, and weight.
Moreover, in connectors, the metal shell is designed to provide a reliable ground connection. It serves as the ground conductor, establishing an electrical connection between the connected components and a common ground reference. This is particularly important in applications where electrical equipment needs to be grounded to prevent the buildup of static electricity, protect against electrostatic discharge (ESD), or provide a path for fault currents. The shell is therefore electrically conductive and designed to make a solid electrical connection with the grounding system of the components it connects.
A connector has to be specifically tailored to facilitate the connection between two components, ensuring reliable electrical contact and secure mechanical attachment. It also has to address the need for a well-designed and efficient connection interface. Moreover, a manufacturing process for producing such a connector has to ensure its proper functionality and compatibility with the intended application.
Specifically, such a connector may be integrated into a printed circuit board (PCB) header, which establishes a mechanical and electrical connection between the PCB and another device/component, such as a plug.
90° (or right-angle) header connectors are quite common, especially in scenarios where space conservation is paramount. The angular design allows cables or mating connectors to be plugged in parallel to the PCB, rather than sticking straight up from it. However, there are challenges associated with designing and manufacturing these connectors.
When the data channels or coaxial conductors are angled, it is important to ensure that the signal integrity of the transmitted signals is maintained. The angle or curve should not introduce signal degradation, impedance mismatch, or undesirable signal reflections. Traditionally, complex multi-part die-cast housings, in particular zinc die-cast housings, have been employed as the metal shell to address these issues, but this can lead to increased complexity in manufacturing and assembly.
In view of the above, it is an object of the present invention to provide a metal shell for a connector for connecting two electrical components and a method of manufacturing a connector for connecting two electrical components, which address the challenges associated with cost, material waste, and RF performance while creating connectors, such as header tubes, with optimized electrical characteristics.
In accordance with the present invention, this object is achieved by the provision of a metal shell for a connector for connecting two electrical components having the features specified in independent claim 1, and by the provision of a method of manufacturing a connector for connecting two electrical components having the features specified in independent claim 15 or independent claim 17. Further advantageous embodiments of the present invention are laid down in the dependent claims.
Specifically, the present invention defined in independent claim 1 provides a metal shell for a connector for connecting two electrical components, said metal shell being adapted to be connected at one end to a first electrical component and at the other end to a second electrical component, wherein the metal shell is a metal tube which is curved along its longitudinal direction.
The advantages of this metal shell for a connector for connecting two electrical components according to the present invention, including cost reduction, improved sustainability, and improved RF performance, can give a company a competitive edge in terms of both cost and performance.
Cost reduction is a significant advantage offered by the use of a curved metal tube as the metal shell. The efficiency and cost-effectiveness of curved metal tubes can lead to savings in manufacturing costs. These cost savings can potentially be passed on to customers, making the connector more affordable and attractive in the market.
Moreover, the utilization of a curved metal tube as the metal shell in a connector can significantly enhance its RF performance. This improvement is particularly valuable in applications where accurate and interference-free signal transmission is of utmost importance.
When it comes to RF signals, impedance matching is crucial for minimizing reflections and maximizing power transfer. With traditional connectors, impedance variations can occur due to manufacturing tolerances or design limitations of the zinc die-cast housings. These variations can result in impedance mismatches, leading to signal degradation and decreased performance.
By using a curved metal tube as a header connector, one can achieve a consistent and controlled impedance along the entire length of the connector. The curve manufacturing process allows for precise control over the dimensions and geometry of the tube, ensuring a uniform cross section. This uniformity minimizes impedance variations and helps maintain a stable and predictable data channel.
This enhanced RF performance offers a competitive advantage over existing connector designs, particularly in industries where reliable signal transmission is critical. Industries such as telecommunications, aerospace, defense, and high-speed data transfer rely heavily on the uninterrupted and accurate transmission of signals. By providing superior RF performance, connectors with curved tubes can meet the stringent requirements of these industries, leading to improved overall system performance and customer satisfaction.
In a preferred embodiment of the present invention, the curved metal tube is manufactured through one or more processes selected from extrusion, stamping and forming, and deep drawing, followed by a bending process, or, alternatively, directly through one or more processes selected from stamping and forming, die casting, deep drawing, and metal injection molding, without a subsequent bending process.
The processes of extrusion, stamping and forming, and deep drawing are chosen based on the desired material properties and structural requirements of the tube. Subsequent to these processes is a bending process, which is precisely calibrated to maintain the integrity of the material and ensure consistent impedance levels. This bending process is configured to accommodate the insertion of internal components without deformation, aligning with the contours of the bent tube to optimize signal transmission and connector assembly.
Extrusion processes generally generate less material waste compared to traditional metal forming methods. The ability to shape the metal into the desired form with minimal material removal means that less raw material is wasted during production. This reduction in material waste contributes to resource conservation and minimizes the environmental impact associated with the extraction and processing of metals.
Employing a stamped-and-formed bent tube as the connector's metal shell introduces cost savings, design versatility, and quicker prototyping. This method streamlines intricate designs, minimizes manufacturing stages, and conserves materials, thereby simplifying production and accelerating assembly timelines.
Alternatively, the desired longitudinal curvature of the metal tube can be directly achieved through the utilization of stamping and forming, die casting, deep drawing, or metal injection molding (MIM) processes. These methods allow for the immediate attainment of the tube's curved shape, thereby eliminating the necessity for any further bending operations subsequent to these processes. This approach ensures efficiency and precision in achieving the required curved form of the metal tube.
Die casting might be particularly favorable when the metal tube requires intricate design features, needs to withstand harsh conditions, or when there is a demand for large volumes. Die casting allows for the creation of complex curved shapes with a high level of detail. Die-cast components can be manufactured with tight tolerances and minimal machining requirements, which is beneficial for ensuring precise fits and consistent quality in connectors.
Furthermore, the present invention defined in independent claim 15 provides a method of manufacturing a connector for connecting two electrical components, comprising the steps of: providing a straight tube made of metal; bending the straight tube into a curved tube with a desired curved angle; inserting at least one conductor into a dielectric insulator; and forming the connector by inserting the dielectric insulator with the at least one conductor inserted therein into the curved tube.
This manufacturing method offers several advantages.
Simplified manufacturing process: By utilizing an extruded and/or stamped-and-formed and/or deep-drawn straight tube as the primary component, the connector design reduces the number of individual parts required. This simplification streamlines the manufacturing process by eliminating the need for complex fabrication methods or assembly steps. The extrusion, stamping and forming, or deep drawin process itself is efficient and can produce consistent and precise tubular shapes.
Reduced assembly time: With fewer separate parts involved, the assembly time required to construct the connector is reduced. The curved metal tube serves as the main structural component, eliminating the need for additional assembly steps associated with joining multiple parts together.
Ideal data channel: The consistent cross section of the curved metal tube along its length helps create an ideal data channel. This consistent shape promotes reliable signal transmission, minimizing signal loss or distortion.
Dielectric design for eliminating air gaps: To ensure optimal electrical performance and prevent the presence of air gaps within the connector, a specific dielectric insulator design can be employed. By compressing the dielectric insulator during the insertion of the conductor(s) and then inserting the assembled insulator into the curved metal tube, any potential air gaps can be eliminated.
Channel separation for multi-position headers: The curved tube can be used to create channel separation, which is useful for multi-position headers. This allows for the connection of multiple components simultaneously while maintaining isolation between the channels.
In summary, the method according to the present invention defined in independent claim 15 combines the use of tube forming and bending techniques and dielectric insulator and conductor insertion techniques to produce a connector having advantages such as simplicity, optimized data transmission, elimination of air gaps, and support for multi-position headers.
Alternatively, the present invention defined in independent claim 17 provides a method of manufacturing a connector for connecting two electrical components, comprising the steps of: providing a straight tube made of metal; inserting at least one conductor into a dielectric insulator; inserting the dielectric insulator with the at least one conductor inserted therein into the straight tube; and bending the straight tube as well as the dielectric insulator and the at least one conductor inserted therein to form a connector having a curved tube with a desired curved angle.
The main difference between the two methods according to the present invention lies in the sequence of steps involved in manufacturing the connector.
In the method defined in independent claim 15, the metal tube is bent first, forming the desired curved angle. Then, the conductor(s) is/are inserted into the dielectric insulator, and the assembled insulator with conductor(s) is inserted into the pre-bent metal tube to form the final connector.
However, in the method defined in independent claim 17, the conductor(s) is/are inserted into the dielectric insulator and then the dielectric insulator with the conductor(s) is inserted into the straight metal tube first. The entire assembly of metal tube, insulator, and conductor(s) is then bent to achieve the desired curved angle, resulting in a connector with a curved tube structure.
Hence, the key distinction between the two methods lies in the timing of bending the metal tube. In the method of independent claim 15, the metal tube is bent before inserting the conductor(s) and insulator, while in the method of independent claim 17, the bending occurs after the conductor(s) and insulator are already inside the straight tube.
This difference in sequence does not result in any difference in the technical advantages already set forth in detail above in connection with the present invention defined in independent claim 15, and which are therefore equally applicable to the present invention defined in independent claim 17.
In addition, smooth and gradual bending of the tube with the conductor(s) and dielectric insulator already inside can help maintain the integrity of electrical signals, reduce signal loss, and mitigate crosstalk and interference. This is particularly important in applications where high-quality signal transmission is critical, such as in telecommunications, data transmission, or audio/video applications.
Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which is made with reference to the accompanying drawings, in which:

Figs. 1a and 1b: illustrate a first embodiment of a connector according to the present invention in the form of a perspective exterior view and a longitudinal sectional view;
Fig. 2: illustrates connectors according to the first embodiment of Figs. 1a and 1b installed into a 4-position PCB header;
Figs. 3, 4, and 5: illustrate second, third, and fourth embodiments of a connector according to the present invention in the form of a perspective exterior view;
Figs. 6a to 6d: illustrates an assembly sequence of a fifth embodiment of a connector according to the present invention in the form of external side views (Figs. 6a to 6d) and additional longitudinal sectional views (Figs. 6c and 6d);
Figs. 7a and 7b: illustrate a sixth embodiment of a connector according to the present invention in the form of a perspective exterior view and a longitudinal sectional view;
Figs. 8a and 8b: illustrate a seventh embodiment of a connector according to the present invention in the form of a perspective exterior view and a longitudinal sectional view;
Figs. 9a to 9c: illustrate an embodiment of a metal tube that can be used in a connector according to the present invention, as a straight tube before bending and as a curved tube after bending;
Figs. 10 to 15: illustrate six different embodiments of a dielectric insulator that can be inserted into a straight tube or a curved tube in the manufacture of a connector according to the present invention; and
Figs. 16 to 18: illustrate the successive process steps in three alternative embodiments of a method of manufacturing a connector according to the present invention.

The drawings depict the design and functionality of a specific type of connector 1 known as a header connector. A header connector is used to establish a connection between a printed circuit board (PCB) (not shown) and another electrical component plugged into a printed circuit board (PCB) header 3 (see Fig. 2), which is a connector interface on the PCB.
The connector 1 consists of a metal shell 2, also called the connector shell or housing, which houses one or more conductors 5 within its inner cavity. One end 2a of the metal shell 2 is connected to the ground of the PCB, while the corresponding end 5a of the conductor(s) 5 forms a conductor pin that is connected to a circuit on the PCB.
On the opposite end 2b, the metal shell 2 is connected to a ground conductor of an electrical component to be plugged into the PCB header 3. The opposite end 5b of the conductor(s) 5 housed within the shell 2 also forms a conductor pin, which is connected to a conductor of the electrical component to be plugged into the PCB header 3. This configuration allows for the transmission of data signals from the PCB (first electrical component) to the electrical component (second electrical component) that is plugged into the PCB header 3.
However, it is to be noted that the benefits of reduced cost, energy consumption, material waste, and optimization of RF performance that can be achieved by applying the present invention can also be extended to other types of connectors used to connect two electrical components. In other words, the advantages of the present invention are not limited to header connectors alone, but they can be extended to other connector types as well.
The embodiment illustrated in Figs. 1a and 1b is a coaxial connector 1 specifically designed for installation in a PCB header 3 as shown in Fig. 2. This connector 1 consists of three elements: an outer metal shell 2; a single conductor 5; and a dielectric insulator 4. The outer metal shell 2 serves as a protective shield for the single conductor 5. It forms a cylindrical cavity in which the conductor 5 is centrally disposed. The dielectric insulator 4 fills the space between the outer metal shell 2 and the single conductor 5, providing electrical insulation and keeping them separate.
At both ends 5a, 5b of the conductor 5, the conductor 5 protrudes from the dielectric insulator 4. These ends 5a, 5b serve as conductor pins for connecting to external electrical components.
One end 5a of the conductor 5 protrudes not only from the dielectric insulator 5, but also beyond the metal shell 2, allowing a solder connection between the conductor pin and the corresponding circuit on the PCB. This ensures a secure electrical connection. The corresponding end 2a of the metal shell 2 features four circumferentially equidistantly spaced pins 6, which connect to the corresponding ground terminals of the PCB, providing proper grounding.
At the other end 5b of the conductor 5, the conductor pin protrudes from the dielectric insulator 4 but remains inside the metal shell 2. This design enables the conductor pin to establish a connection with a corresponding terminal on an external component, like a sensor or an amplifier, that is to be connected to the PCB header 3. This connection enables the electrical signals to be transmitted between the PCB and the external component.
To accommodate space constraints when connecting external components to the PCB, the connector 1 utilizes a curved design. To this end, the metal shell 2 is configured as a curved metal tube 10, which may be curved along its longitudinal direction at an angle of approximately 90°. This allows for efficient placement and connection of the external components. However, when tubes are curved, the curving radius and angle are critical factors affecting their RF performance. Sharp curves or excessively small radii can introduce signal reflections, impedance mismatches, and increased signal loss.
The curved metal tube 10 may be obtained from a straight metal tube 7 manufactured by means of extrusion and/or stamping and forming and/or deep drawing techniques. Subsequent to this tube manufacturing process, a bending operation is executed on the metal tube to achieve its specified curved configuration.
Bending involves deforming the material along a specific axis, allowing it to take on a curved or angled form. By bending the extruded and/or stamped-and-formed and/or deep-drawn metal tube, the connector 1 achieves the required curved angle without the need for more complex assembly operations. This helps to significantly reduce manufacturing costs and material consumption.
However, in an alternative embodiment, the fabrication of the curved metal tube 10 can be directly achieved using a die casting and/or a molding, specifically a metal injection molding (MIM), and/or a stamping and forming and/or a deep drawing method. This approach eliminates the need for any additional bending processes.
In any case, the curved metal tube 10 advantageously ensures a nearly constant cross section along the 90° extension of the data channel. This eliminates the cross section and impedance variations that can affect the RF performance of conventional complex, multi-part connectors. The curved metal tube design thus ensures high RF performance.
The PCB header 3 shown in Fig. 2 is an injection molded plastic part used as a connection interface in a PCB assembly. It serves to establish a connection between the PCB itself and another electrical component, such as a sensor, amplifier, or any other electrical device, which can be plugged into the header's ports.
The PCB header 3 in this case is a 4-position PCB header 3. The four positions are formed by the ends 2a, 2b, 5a, 5b of four connectors 1 that are angled at 90°, as shown in Figs. 1a and 1b. These connectors 1 are inserted into the PCB header 3 in a positive manner, meaning they fit securely and cannot be easily removed without intentional effort. At one end 2a, 5a of the connectors 1, the pins 6 of the metal shells 2 and the conductor pins of the conductors 5 are soldered to the PCB. This soldering process creates both a mechanical and electrical connection between the PCB header 3 and the PCB, ensuring a secure and reliable connection for the transmission of high-frequency data signals. At the other end 2b, 5b of the connectors 1, the metal shells 2 and conductors 5 form the terminals for making a mechanical and electrical connection with the corresponding terminal pins of the external electrical component that is to be connected to the PCB header 3.
In summary, the four connectors 1 incorporated in the 4-position PCB header 3 facilitate high-frequency data transmission between two electrical components: the PCB (first electrical component) and an external electrical component (second electrical component) that is meant to be connected to the PCB header 3. The high-frequency data transmission allows for the exchange of information between the two electrical components, enabling them to work together seamlessly.
The alternative embodiments of the coaxial connector 1 shown in Figs. 2 through 4 differ from the first embodiment shown in Fig. 1 in the following ways.
In Fig. 1, the curved metal tube 10 of the coaxial connector 1 is curved along its longitudinal direction so as to have a curved angle of approximately 90°. However, it is preferable that the curved angle be equal to or less than 90°. By reducing the curved angle, the vertical space requirement of the connector 1 (perpendicular to the plane of the PCB) can be further reduced. This reduction in vertical space is advantageous in terms of minimizing the overall size of the connector 1.
In the embodiment shown in Fig. 3, the curved metal tube 10 has along its longitudinal direction a curved angle of 45° with respect to a horizontal plane (parallel to the plane of the PCB). This 45° curved angle results in a significant reduction in the height of the connector 1. This reduction in height is particularly advantageous when dealing with limited space available in PCB assembly structures. Therefore, a curved angle equal to or less than 45° is even more preferred in the present invention.
In all embodiments, including the alternative ones, the pins 6 of the curved metal tube 10 and the conductor pin at the one end 5a of the central conductor 5 are formed to extend in a vertical direction (perpendicular to the plane of the PCB). This vertical extension allows for optimal soldering in through holes that are formed in the PCB. By extending the pins 6 vertically, the connection between the coaxial connector 1 and the PCB can be securely established.
As shown in Fig. 4, the curved metal tube 10 of the coaxial connector 1 has a large curve radius. On the one hand, this large curve radius requires only a very small vertical space (perpendicular to a plane of the PCB). On the other hand, this large curvature gently and gradually curves the conductor 5, avoiding sharp changes in direction that could induce stress peaks and lead to a higher local degradation of the conductor 5, which in turn could potentially damage the high-frequency data transmission between the PCB and the other external electrical component.
The embodiment shown in Fig. 4 may be realized by first bending the tube to its maximum capacity (a full bend, e.g. a 90° bend) and then cutting off a portion of the bent tube. The resulting section of the tube has a large bend radius compared to its linear extension. Cutting off a portion of a fully bent tube is essentially the same as "taking a slice" of that bend. The bend of the cut-off portion would represent a specific segment of the original full (e.g. 90°) bend.
Although the same curved angle (90°) is seen in Fig. 5 as in Fig. 1, there is a change in the way the pins 6 are formed at one end 2a of the metal shell 2 compared to the previous embodiments shown in Figs. 1 to 4. In these previous embodiments, the pins 6 were formed by stamping into the one end 2a of the curved or straight tube 10, 7 forming the shell 2. However, in Fig. 5, the pins 6 are preformed in an additional annular part 8 that is firmly attached to the one end 2a of the cylindrical metal shell 2. This means that the pins 6 are not formed directly on the shell 2 itself but on an additional part 8 that is connected to the shell 2. By using this additional part 8, the need for the stamping step shown in step c. of Fig. 16, step b. of Fig. 17, and step b. of Fig. 18 is eliminated.
This approach - shifting the stamping process from the metal shell 2 to the additional part 8 (PCB pin piece) - offers a pragmatic solution to a manufacturing challenge. Stamping on a smaller, more manageable component like the additional part 8 (PCB pin piece) is simpler than stamping on a larger, more rigid structure such as the metal shell 2. This leads to more consistent results and a higher yield of acceptable parts. Moreover, if changes need to be made, it is often more cost-effective and faster to adjust a smaller component than to reconfigure a major part. Therefore, if the stamped design on the PCB pin piece needs to be altered, the change can likely be made with minimal disruption to the overall production process.
By using an additional part 8 with preformed pins 6, the overall production process becomes simpler and less expensive. Connecting an additional part 8 with the preformed pins 6 to the metal shell 2 is relatively easier compared to performing an additional stamping step on an extruded, stamped-and-formed, or deep-drawn tube 7, 10 (whether it is straight or curved). The connection of the additional part 8 can be achieved through various methods such as welding, press-fitting, or mechanical fastening, depending on the specific design and requirements.
The assembly process illustrated in Figs. 6a to 6d outlines the sequential manufacturing steps for a connector 1 according to a preferred embodiment of the invention. This involves the use of a curved metal tube 10 with a large curve radius, as detailed in Fig. 4, which has been discussed in detail above.
Fig. 6a shows the individual components from which such a connector 1 is made. Firstly, there is the metal shell 2, which is a curved metal tube 10 which is curved along its longitudinal direction in such a way that the arc is cut before it exceeds a full 90° curve. This curved metal tube 10 is already equipped at one of its ends 2a with vertically angled pins 6, which are used for electrical and mechanical connection to an electrical component. The dielectric 4 consists of two insulator halves 4a, as shown in Fig. 12. The conductor 5 is also vertically angled at one of its ends 5a for connection to an electrical component, such as a printed circuit board.
Transitioning from Fig. 6a to Fig. 6b, the assembly of the connector's internal structure commences by uniting two semi-cylindrical insulator halves 4a, 4b, as shown in Fig. 12, thereby encapsulating the conductor 5. Consequently, the conductor 5 is routed through a cylindrical central aperture formed by the union of the insulator halves 4a, 4b. This arrangement allows both ends 5a, 5b of the conductor 5 to extend beyond the confines of the dielectric insulator 4, enabling electrical connections of the conductor 5 with the respective external electrical components.
As illustrated in Fig. 6c, the dielectric insulator 4 with the embedded conductor 5 is initially inserted into the curved metal tube 2 following the insertion direction I corresponding to the curved longitudinal axis direction of the curved metal tube 10. This insertion process is notably facilitated by the tube's large curving radius and small curving angle. Specifically, the design ensures that during insertion, the end 5b of the conductor 5 does not come into contact with the interior surface of the curved tube 10, avoiding potential obstructions or damage to either the conductor 5 or the curved tube 10. This seamless insertion, free from any collision risk, is depicted in the longitudinal sectional view in the lower part of Fig. 6c.
The insertion of the dielectric 4 with the embedded conductor 5 into the curved metal tube 10 is finally completed with the formation of the connector 1 according to the present invention as shown in Fig. 6d, where the dielectric 4 with the embedded conductor 5 is inserted until one end face of the dielectric insulator 4 is flush with the insertion opening 11 of the curved metal tube 10. The end 5b of the conductor 5 which protrudes from the dielectric insulator 4 in the insertion direction I, as shown in the sectional view in the lower part of Fig. 6d, is located just before the other opening 12, opposite the insertion opening 11, as seen in the insertion direction I, and thus remains protected inside the curved metal tube 10.
As also visible from the external side view in the upper part of Fig. 6d, one of the pins 6' at the end 2a of the curved metal tube 10 can be bent inward in the radial direction of the curved metal tube 10 upon completion of the insertion process. In this manner, the radially inward-bent pin 6' can serve as an additional form-fitting lock to securely prevent the unintentional dislodgement of the dielectric 4 from the insertion opening 11 of the curved metal tube 10.
As a result, the assembly sequence shown in Figs, 6a to 6d provides a particularly simple and economical method of assembling the connector 1 according to the present invention.
The present invention is not only intended to cover coaxial systems (such as shown in Figs. 1 to 5) but also differential pair systems (such as shown in Figs. 7a to 8b).
The differential pair system of Figs. 7a and 7b has differential pair connectors 1 with a rectangular curved tube 10 as an outer metal shell 2 to act as a shield to prevent interference from external sources. The inner cavity of the curved tube 10 contains two conductors 5 that are parallel to each other and separated from each other and from the outer metal shell 2 by a dielectric insulator 4. The parallel arrangement ensures that the signal paths for both conductors 5 within the outer metal shell 2 are of equal length.
As shown in Fig. 7a, the differential pair system uses two parallel connectors 1 curved at 90°, respectively. The 90° curved configuration allows for vertical alignment of the connection ports formed by the ends 2b of the curved metal tubes.
On the opposite ends 2a of the curved metal tubes 10, four pins 6 are respectively stamped to establish a connection to the PCB ground. These pins 6 provide grounding for the system, helping to mitigate noise and ensure proper signal integrity. Additionally, there are two conductor pins formed by the ends 5a of the conductors 5 that protrude from the dielectric insulator 4 and the curved metal tube 10. These conductor pins are connected to the PCB circuits and carry the differential signals.
The differential pair connector 1 of Figs. 8a and 8b is also designed to facilitate the transmission of differential signals between a PCB and an external electrical component, such as a sensor or amplifier.
This connector 1 also consists of two conductors 5 running in parallel inside an outer metal shell 2 that acts as a shield. The outer metal shell 2 is a curved tube 10, which offers advantages in terms of cost efficiency, material and energy savings, and improved radio frequency (RF) performance due to its uniform cross section. In this particular embodiment, the cross section of the curved tube 10 is in the form of a flattened rectangle with rounded sides. This shape can be achieved by using suitable tools during the straight tube manufacturing (e.g. extrusion, stamping and forming, or deep drawing) process and then bending the tube to the desired angles, 90° in the case of Figs. 8a and 8b.
For connecting the curved metal tube 10 to the PCB ground, there are two stamped pins 6 located at one end 2a of the tube 10. These pins 6 serve as the grounding connection points. At the corresponding ends 5a of the two conductors 5, there are two conductor pins that protrude vertically from the metal tube 10. These conductor pins are used to establish the electrical connection with the circuit on the PCB.
The differential signals are transmitted along the two conductors 5 from the one end 5a to the other end 5b, respectively. Although these other ends 5b of the conductors 5 also protrude from the dielectric insulator 4, they are still received within the curved metal tube 10 to maintain the shielding. Consequently, at these other ends 5b, conductor pins are formed to transmit the differential signals to corresponding connector pins of an external electrical component. Hence, the conductor pins at both ends 5a, 5b of the conductors 5 enable the transmission of data between the PCB and the external component.
It is important to note that the embodiments of Figs. 6a to 7b are not exhaustive, and there can be variations in the design of differential pair header connectors. This can include different curved angles, such as reduced angles of 45° or less, as well as header connectors with larger radii, as shown in Figs. 3 and 4. Also, there may be alternative solutions that incorporate additional parts 8 with preformed pins 6, as shown in Fig. 5, to accommodate specific requirements or applications.
Figs. 9a to 9c show a method for manufacturing the curved tube 10 used as the outer metal shell 2 of the connector 1, starting from an (extruded and/or stamped-and-formed and/or deep-drawn) straight tube 7. This straight tube 7 is intentionally (deliberately) designed with structural weak points in the form of wedge-shaped notches 2c. These notches are located on the underside of the straight tube 7, which becomes the side of the curved tube 10 with a smaller curving radius (cf. Fig. 9c).
The purpose of incorporating these wedge-shaped notches 2c is to facilitate the bending process of the extruded and/or stamped-and-formed and/or deep-drawn straight tube 7 around a bending axis (center axis of curvature) orthogonal to the longitudinal axis of the tube, resulting in a reduced bending stiffness. This reduction in bending stiffness makes it easier to bend the tube at a desired curved angle (for example, 90° angle as in Fig. 9c), forming the protective outer shield of the connector 1.
This bending process closes the wedge-shaped notches 2c in the curved tube 10 so that it can serve as an outer shield of the connector 1, providing reliable shielding against electrical and mechanical interference for the conductor(s) 5 inside.
The main advantage of introducing these intentional structural weak points is that it significantly reduces the energy consumption required during the production process of the curved tube 10.
It is worth noting that the wedge-shaped notches 2c mentioned in the above are just one example of intentional structural weak points that can be introduced into the metal shell 2.
Other types of structural weak points, such as cracks or apertures, can also be utilized to achieve similar benefits in terms of facilitating the bending of the metal tube 10.
Concluding, incorporating structural weak points in the metal shell 2 offers advantages in terms of energy and cost savings during production, while still ensuring the desired functionality and protection provided by the metal shell 2 in the connector 1.
Figs. 10 to 15 show alternative embodiments of dielectric insulators 4 that can facilitate the bending process and/or insertion into tubes 7, 10.
These dielectric insulators 4 are made of dielectric materials, which are non-conductive and provide electrical insulation between the inner conductor(s) 4 and the meta shell 2 of the conductor 1. Dielectric materials have high resistivity and low dielectric constant, making them suitable for this purpose. Such dielectric materials can be certain polymers or elastomers that have the ability to deform without losing their insulating properties.
When it comes to facilitating the bending process and/or insertion of dielectric insulators into tubes, there are different techniques and features that can be employed:
With a view of reducing the bending stiffness (increasing the bending flexibility) the dielectric insulator 4 illustrated in Fig. 10 has been designed to include a plurality of wedge-shaped notches 4c (similar to what has been described above in connection with the metal shell 2), allowing the dielectric insulator 4 to bend along with the tube during the bending process. Again, it is noted that instead of notches 4c also other types of structural weak points (such as cracks or apertures) can be provided in the dielectric insulator 4 to facilitate bending of the material. These structural weak points act as predetermined points of stress concentration, allowing the material to deform or bend more easily in those areas.
In accordance with Fig. 11, the geometric design of the dielectric insulator 4 can also influence its bending behavior. The illustrated dielectric insulator design with X-shaped cross section introduces weak points making it more susceptible to bending or torsional forces. When a force is applied to this structure with an X-shaped cross section, the load tends to concentrate at the intersection points of the X. These intersection points become stress concentration areas, where the applied force can cause bending or deformation to occur more readily. Computer-aided design (CAD) tools and simulation techniques can be used to analyze and optimize the geometric design for desired mechanical properties.
In accordance with Figs. 11, 12, and 13, the dielectric insulator 4 can be designed with a split or segmented structure, which allows it to be easily inserted into the tube. This split or segmented design enables the dielectric insulator 4 to expand or compress during insertion and then regain its original shape once in place.
According to the configuration for the dielectric insulator 4 shown in Fig. 12, the dielectric insulator 4 is divided into two identical dielectric insulator halves 4a, and when viewed in cross section, there is a separation line between these halves 4a that runs parallel to the bending axis (center axis of curvature) of the metal tube 10. This configuration is designed to allow for easier deformation or bending of the overall system.
By having two identical dielectric insulator halves 4a, it is possible to achieve more flexibility and adaptability when bending the system. The separation line running parallel to the bending axis (center axis of curvature) of the metal tube 10 allows the insulator halves 4a to move independently during deformation, accommodating the bending motion without causing excessive stress or strain on the dielectric insulator 4.
This configuration can also be advantageous in applications where the connector 1 needs to undergo bending or flexing while maintaining electrical insulation. By incorporating a divided dielectric insulator 4 with a separation line aligned with the bending axis (center axis of curvature), the system can better withstand mechanical stresses without compromising the insulation properties of the dielectric insulator material.
Fig. 13 shows a dielectric insulator quarter 4b. The dielectric insulator 4 in the connector 1 consists of four of these dielectric insulator quarters 4b, with each quarter 4b covering 90° of the inner volume of the connector. The separation lines between these quarters 4b have specific orientations when viewed in cross section of the connector 1. The first separation line between the dielectric insulator quarters 4b is parallel to a bending axis (center axis of curvature) of the metal tube 10. This means that it runs in the same direction as the bending axis (center axis of curvature) around which the metal tube 10 is bent. The second separation line between the dielectric insulator quarters 4b is perpendicular to the bending axis (center axis of curvature) of the metal tube 10. This means that it is positioned at a 90° angle with respect to the bending axis (center axis of curvature) around which the metal tube 10 is bent.
The purpose of these specific orientations of separation lines is to help to improve the flexibility and bending capability of the overall structure. By dividing the dielectric insulator into quarters and orienting the parting lines in this manner, the insulator can better accommodate bending motions without overstressing or compromising its structural integrity.
The use of a plurality of dielectric insulator disks 4d (see Fig. 14) arranged in succession along the longitudinal direction of the connector's metal shell 2 is also a technique to improve the bendability of the dielectric insulator 4 during the manufacturing process. This arrangement helps to maintain the electrical insulation properties while allowing connector 1 to be bent to the desired curved angle without compromising its functionality.
By dividing the dielectric insulator 4 into multiple disks 4d, the overall flexibility of the dielectric insulator 4 is increased. Each disk 4 can move independently, allowing the connector 1 to have a smooth bending contour without putting excessive strain on the dielectric insulator 4.
The dielectric insulator 4 can be subjected to a preforming operation so as to take specific shapes that are conducive to bending. For example, as shown in Fig. 15, the preformed dielectric insulator 4e can be configured to have a curved shape with gradual curves or angled sections to approximately match the curved shape of the curved metal tube 10 forming the protective outer shield of the connector 1.
By using a preformed dielectric insulator 4e, the manufacturing process becomes more efficient and precise since the insulator already has the desired shape or curvature. This eliminates the need for complex bending or molding operations on the insulator itself, simplifying the production process while ensuring consistent quality.
A set of possible manufacturing steps for manufacturing a connector 1 for connecting two electrical components, in particular a connector 1 in the form of a 90° angled header tube (90° angled coaxial tube) to be integrated into a PCB header 3 for transmitting data signals from a circuit of the PCB to a further electrical component (such as a sensor or an amplifier) to be plugged into the PCB header 3 will be outlined in the following by referring to the steps a. to g. shown in Fig. 16. These steps can vary depending on the specific requirements and design considerations.
The manufacturing process begins with the production of a straight metal tube 7 using one or more of the following techniques: extrusion, stamping and forming, or deep drawing. These processes are selected according to the specific requirements of the design, and each makes a unique contribution to the material properties and structural integrity of the tube, which are critical to the subsequent manufacturing steps.
In accordance with steps a. and b. in Fig. 16, a bending machine, also known as a bender, is used to bend the extruded and/or stamped-and-formed and/or deep-drawn straight metal tube 7 into the desired curved angle. The process involves feeding this straight tube 7 into the bender (step a. in Fig. 16), which then applies force to deform the tube and achieve the desired curved angle (step b. in Fig. 16).
There are various techniques and tools used in the bending process, depending on the specific requirements and characteristics of the tube. Bending mandrels and bending rollers 9 (as shown in steps a. and b. of Fig. 16) are two techniques used in the tube bending process, and they play crucial roles in achieving accurate and desired results.
Bending mandrels provide internal support to the tube during bending, ensuring that the inner wall maintains its shape and prevents wrinkling or collapsing. The mandrels are inserted into the tube before bending, and their size and shape are chosen based on the tube diameter and desired bending angle. They act as a form or support around which the tube can bend, helping to maintain a smooth and consistent bend radius.
On the other hand, bending rollers 9, as shown in steps a. and b. of Fig. 16, are responsible for applying pressure to the outside of the tube as it moves through the bending machine. This pressure gradually deforms the tube, causing it to bend along a specific radius and angle.
The number and arrangement of bending rollers 9 can vary depending on the complexity of the desired bend and the level of precision required. In simpler bends, two rollers 9, as in steps a. and b. of Fig. 16, may be sufficient, whereas more complex bends may require a greater number of rollers 9 to achieve the desired shape accurately.
The arrangement of the rollers 9 also depends on the specific requirements of the bending process. Some machines use three rollers 9, where two are positioned on one side of the tube, applying pressure from different angles, while the third roller is positioned on the opposite side. This setup helps create a more uniform and controlled bend.
In addition to the number and arrangement of rollers 9, other factors such as the size and material of the tube, as well as the bending machine's capabilities, can influence the bending process. Advanced bending machines may offer programmable controls that allow operators to precisely adjust the roller pressure, speed, and other parameters to achieve the desired bend accurately.
In some cases, both bending mandrels and rollers 9 are used together to achieve the desired bending outcome. The mandrel supports the inner wall while the rollers 9 apply pressure to deform the outer wall. This combination allows for more control over the bending process, resulting in accurate and consistent bends.
In step c. of Fig. 16, the curved tube 10 is first cut to a desired length using a clamping mechanism or a pipe cutting guide to secure it and prevent movement during the cutting process. This ensures a straight and accurate cut. An appropriate cutting technique (such as, sawing, shearing, or laser cutting) should be selected depending on the tube material and required precision.
Step c. of Fig. 16 also involves stamping a plurality of pins 6 into one end of the curved tube 10 to create termination points for connection to the PCB ground. A stamping tool, also known as a stamping die, needs to be created to match the pin layout. This tool is typically made from hardened steel or other suitable materials. The stamping tool will have the negative impression of the PCB pin arrangement. The tube is secured in a fixture or jig to hold it in place during the stamping process. The stamping tool is aligned with the end of the tube, ensuring that the pins' position matches the desired configuration. A hydraulic press or another suitable method applies controlled pressure to the stamping tool. The pressure should be sufficient to impress the PCB pin pattern onto the tube's end while maintaining accuracy and precision.
Bending or forming the plurality of pins 6 on the curved tube 10 to establish a reliable electrical connection between the tube and the PCB ground occurs in step d. of Fig. 16. The tube, with its pins 6 extending outward, is positioned in a bending tool. The tube is carefully aligned to ensure that the pins 6 are positioned correctly for bending. Once the tube is aligned, gradual and controlled force is applied to the pins 6 using a bending mechanism. As the force is applied, the pins 6 on the tube start to bend gradually. After the bending process is complete, it is important to carefully inspect the bent pins 6 for any defects or inconsistencies.
Plating the curved tube 10, as in step e. of Fig. 16, provides several benefits, including improved appearance, corrosion resistance, conductivity enhancement, and environmental protection. The specific plating process will depend on the desired properties and the materials involved. Plating methods include electroplating, electroless plating, physical vapor deposition (PVD), chemical vapor deposition (CVD), or painting techniques. The choice of plating method will depend on factors such as the desired thickness, the type of plating material, and the complexity of the tube's shape. It is important to note that plating the curved tube 10 is an optional step and may not be necessary for all applications.
Subsequently, the conductor 5, typically in the form of a wire or cable, is provided which is responsible for transmitting the data signals between the two connected electrical components and is typically also referred to as the signal conductor or signal pin. To enhance the electrical performance or achieve other objectives, the signal conductor 5 may be plated in advance. Plating involves depositing a thin layer of metal onto the surface of the conductor 5. Plating materials used in connectors 5 include gold, tin, nickel, and silver.
According to step f. in Fig. 16, the plated conductor 5 is inserted into a dielectric insulator 4e made of a non-conductive flexible material which has been subjected to a preforming process so that it acquires a curved shape similar to that of the curved tube 10. The preformed dielectric insulator 4e acts as an electrical insulator, providing insulation and separation between the conductor 5 carrying the data signal and the curved tube 10 forming the outer shield of the connector 1. The preformed dielectric insulator 4e is typically made of a polymer or elastomer material selected for its electrical insulation properties, flexibility, and durability. Common materials used for dielectric insulators in connectors include polyethylene (PE), polypropylene (PP), polytetrafluoroethylene (PTFE), polyvinyl chloride (PVC), and silicone rubber.
There are a few considerations when inserting the plated conductor 5 into a dielectric insulator 4. It may be necessary to drill or punch a hole or channel through the dielectric insulator 4, or an existing hole or channel can be used. The size and shape of the hole or channel should match the dimensions of the plated conductor 5 to be inserted. The plated conductor 5 can be positioned in the center or along the sides of the dielectric insulator 4, depending on the specific design requirements. Depending on the materials involved and the fit of the plated conductor 5 in the dielectric insulator 4, it may be necessary to apply a lubricant to facilitate the insertion process. Lubrication can help reduce friction and prevent damage to the conductor 5 or dielectric insulator 4. Insertion of the plated conductor 5 is accomplished by carefully guiding the plated conductor 5 into the insertion point of the dielectric insulator 4 while applying gentle pressure to ensure that the conductor 5 is properly aligned with the hole or channel. Care must be taken to avoid applying excessive force that could damage the dielectric insulator 4 or cause the conductor 5 to deform. Once the conductor 5 is fully inserted into the dielectric insulator 4, it may be necessary to secure it in place to prevent unintentional movement. This can be accomplished by various methods, such as gluing, mechanical fastening, or heat-shrink tubing.
In step g. of Fig. 16, the connector 1 is formed by carefully inserting the preformed dielectric insulator 4e with the conductor 5 inserted therein (from step f. of Fig. 16) into the curved tube 10. By incorporating controlled compression during the insertion process, one can enhance the contact between the preformed dielectric insulator 4e and the curved tube 10, minimizing the likelihood of air gaps. This helps ensure proper insulation and improves the overall performance of the connector 1. Moreover, it has to be ensured that the preformed dielectric insulator 4e and conductor 5 are securely disposed within the curved tube 10, allowing for proper electrical connections. It is possible to make any necessary adjustments to ensure a secure fit. Additional measures (like crimping, soldering, or fastening) may be employed to enhance the mechanical stability and electrical conductivity of the connector 1 and, thus, create a strong and reliable connection. Once the preformed dielectric insulator 4e and the conductor 5 are in place inside the curved tube 10, the assembly is inspected for remaining air gaps between the insulator and the tube and for proper alignment and connection.
Finally, in step g. of Fig. 16, a conductor pin formed by one end 5a of the conductor 5 which protrudes from the preformed dielectric insulator 4e and the curved metal tube 10 is bent to a position adapted for connection to an electrical component, in this case the PCB. To connect the conductor pin to the signal circuit on the PCB, the conductor pin (exposed end 5a of the conductor 5) is bent vertically or at a suitable angle for easy connection. This bending allows the pin to be aligned with the appropriate pad or via on the PCB for electrical contact. There are several methods for making this connection, including soldering, which is commonly used. In soldering, heat is applied to melt a solder alloy that forms a conductive bond between the pin and the pad or via.
In the alternative second manufacturing method of Figs. 16, the basic method steps involved in manufacturing the connector 1 are the same as in the manufacturing method of Fig. 16 described in detail above. However, the order of these method steps is different in Figs. 16 and 17, resulting in distinct advantages. Therefore, the method steps of Fig. 17 are only briefly summarized below and the focus is on the specific differences in the order of the method steps of Fig. 17 compared to the order of the method steps of Fig. 16 and the resulting advantages.
The manufacturing method steps a. to f. of Fig. 17 for a connector 1 in the form of a header tube (coaxial tube) are the following:
The first step a. in the method of manufacturing the connector 1 is to cut the raw tube material in the form of an extruded and/or stamped-and-formed and/or die-cast and/or deep-drawn and/or metal-injection-molded straight tube 7 to the desired length.
Since the tube is intended to be used as a header tube (see Fig. 2), the next step b. is to stamp (or alternatively attach, see Fig. 5) a plurality of pins 6 onto one end of the extruded and/or stamped-and-formed and/or deep-drawn straight tube 7. These pins 6 allow the tube to be easily connected to electronic circuits on the PCB.
Plating is performed in step c. to enhance the tube's corrosion resistance, conductivity, and aesthetic appearance. The extruded and/or stamped-and-formed and/or deep-drawn straight tube 7 can undergo processes such as electroplating, where a metal coating is deposited onto the surface, or other plating methods depending on the desired properties.
In the present case, the connector 1 to be manufactured is a coaxial connector, so that in step d. one inner conductor 5 (typically a wire) is plated and inserted into the center of a dielectric material 4. The dielectric material 4 provides insulation between this inner conductor 4 and the outer shield.
According to step e., the dielectric insulator 4 with the one conductor 5 centrally inserted therein from step d. is then inserted into the plated straight tube 7 from step c. This step e. assembles the coaxial structure with the central inner conductor 5 surrounded by the dielectric insulator 4 and both enclosed within the straight tube 7.
Finally, in step f., due to the limited space in a PCB header 3 (see Fig. 2), the straight tube 7, together with the dielectric insulator 4 and the central inner conductor 5 inserted therein, must be bent into a specific curved shape. This can be done using bending machines, press brakes, or other methods suitable for the tube material and geometry.
Bending the entire connector assembly of tube, insulator, and conductor at the end of the manufacturing method, as disclosed in Fig. 17, offers several advantages over bending only the tube and inserting the insulator and conductor into the bent tube, as disclosed in Fig. 16.
By inserting the dielectric insulator 4 with the conductor 5 into the straight tube 7 in accordance with step e. of Fig. 17, the assembly process becomes simpler and more straightforward. It may be easier to insert the components into the straight tube compared to a pre-bent tube, especially if the bending radius is tight or complex. This can save time and reduce the chances of errors during assembly.
Bending the entire connector assembly at the end in accordance with step f. of Fig. 17 ensures that the tube, insulator, and conductor are bent as a single unit. This can result in better alignment and uniformity of the bent structure, minimizing any potential stress concentrations or weak points that could occur if bending was performed separately. Uniform bending of the entire connector assembly can contribute to creating an ideal data channel or transmission path. When the tube, insulator, and conductor are bent as a single unit, it helps maintain a consistent cross section along the entire length of the bent structure. A uniform cross section is desirable for maintaining signal integrity in various applications, especially in cases where the connector assembly is used for data transmission, such as in high-frequency or high-speed communication systems. Any irregularities or variations in the cross section can lead to signal distortion, reflections, or loss, potentially degrading the performance of the data channel.
By postponing the bending step f. of Fig. 17 until the end, it allows for greater flexibility in design and customization. The straight tube 7 can be manufactured in a standard form, and then the desired bend can be applied according to specific requirements or variations in the final product. This approach allows for easier adaptation to different form factors or customer preferences without the need for custom tooling or additional manufacturing steps.
Bending the entire connector assembly at the end may also lead to cost savings in terms of production and tooling. It eliminates the need for separate bending processes for the tube and the assembled components (insulator and conductor), reducing equipment and setup costs. It also streamlines the manufacturing workflow by consolidating operations, potentially improving efficiency and productivity.
In the manufacturing method of Fig. 18, the initial steps a. to e. (that is, cutting the tube to length, punching the pins into the tube end, plating the tube, plating the conductor and inserting it into the dielectric material, inserting the conductor and dielectric material into the plated tube, and bending the tube with the dielectric material and the conductor inserted therein) remain the same with the exception of the bending angle produced in this last bending step e.
After inserting the internal components (insulator with embedded conductor), the tube is bent, but with a smaller angle of less than 45°. This is advantageous to adapt the connector 1 to its specific mounting environment, such as a PCB header 3 (see Fig. 2), and reduce the overall height of the connector 1 and surrounding components.
However, the small bending angle causes the pins (pins 6 at the end 2a of the curved tube 10 and conductor pin at the end 5a of the conductor 5) to be bent at the same small angle of less than 45°. However, this bent position is not ideal for proper connection to ground and PCB circuits.
To solve this problem, a final step g. is added to the manufacturing method of Fig. 18, where the pins (both the tube pins and the conductor pin) are further bent to a vertical position using suitable bending tools. This additional bending operation in step g. of Fig. 18 aligns the pins perpendicular to the horizontal starting position.
By bending the pins to a vertical position, they can be easily connected to the PCB's ground and circuits. This connection is typically made by soldering the pins to the appropriate pads or traces on the PCB.
Ensuring a secure and reliable connection between the connector and the PCB is essential for proper electrical conductivity and functionality. By bending the pins into a vertical position and soldering them to the PCB, a strong and reliable electrical connection is established, allowing the connector to effectively transfer signals or power between the PCB and external components.
The manufacturing methods described above offer several advantages over traditional connector manufacturing techniques. Instead of relying on casting and molding processes, these methods introduce alternative approaches that address the limitations of the existing methods.
One of the drawbacks of traditional techniques is their high cost. The above-described manufacturing methods minimize costs and material usage, resulting in significant cost savings compared to traditional techniques. This cost-effectiveness is achieved by optimizing the manufacturing process and reducing the amount of material required.
Furthermore, the above-described manufacturing methods are specifically designed to improve RF performance, which is crucial in connectors used in industries such as telecommunications, electronics, and wireless communications. By optimizing the manufacturing process for RF performance, the signal quality and reliability of the connectors are enhanced. This improvement in RF capabilities contributes to the overall quality and functionality of the connectors.
In summary, the above-described manufacturing methods offer an efficient and cost-effective solution for producing connectors with improved RF performance. By departing from traditional casting and molding processes, these methods optimize manufacturing costs and material usage while maximizing the RF capabilities of the connectors. This innovation has the potential to benefit industries that heavily rely on connectors, such as telecommunications, electronics, and wireless communications.

List of Reference Signs

1: connector
2: (outer) metal shell
2a: one end of metal shell/curved tube
2b: other end of metal shell/curved tube
2c: notch in metal shell/curved tube
3: printed circuit board header
4: dielectric insulator
4a: dielectric insulator halve
4b: dielectric insulator quarter
4c: notch in dielectric insulator
4d: dielectric insulator disk
4e: preformed dielectric insulator
5: conductor
5a: one end of conductor
5b: other end of conductor
6: pin
6': radially inward bent pin
7: straight metal tube
8: additional part
9: bending rollers
10: curved (metal) tube
11: insertion opening
12: other opening
I: insertion direction

Claims

Metal shell (2) for a connector (1) for connecting two electrical components, said metal shell (2) being adapted to be connected at one end (2a) to a first electrical component and at the other end (2b) to a second electrical component,
characterized in that
the metal shell (2) is a metal tube (10) which is curved along its longitudinal direction.
Metal shell (2) for a connector (1) for connecting two electrical components according to claim 1, wherein:
the curved metal tube (10) is manufactured through one or more processes selected from extrusion, stamping and forming, and deep drawing, followed by a bending process; or

the curved metal tube (10) is directly manufactured through one or more processes selected from stamping and forming, die casting, deep drawing, and metal injection molding, without a subsequent bending process.
Metal shell (2) for a connector (1) for connecting two electrical components according to claim 1, wherein
the metal shell (2) is provided at the one end (2a) with a plurality of pins (6) to be connected to the first electrical component.
Metal shell (2) for a connector (1) for connecting two electrical components according to claim 2, wherein
the plurality of pins (6) are stamped into the one end (2a) of the metal shell (2).
Metal shell (2) for a connector (1) for connecting two electrical components according to claim 2, wherein
the plurality of pins (6) are formed in an additional part (8) firmly attached to the one end (2a) of the metal shell (2).
Metal shell (2) for a connector (1) for connecting two electrical components according to any one of claims 3 to 5, wherein
at least one pin (6') of the plurality of pins (6) is configured to bend in a radial inward direction of the metal shell (2).
Metal shell (2) for a connector (1) for connecting two electrical components according to any one of claims 1 to 6, wherein
the curved metal tube (10) has a curved angle of equal to or less than 90°, preferably equal to or less than 45°, and/or

the curved metal tube (10) is a tube with a cut-off full bend.
Connector (1) for connecting two electrical components, comprising:
the metal shell (2) according to any one of claims 1 to 7;

a dielectric insulator (4) fixedly disposed within the metal shell (2); and

at least one conductor (5) fixedly disposed within the dielectric insulator (4) and adapted to be connected at one end (5a) to the first electrical component and at the other end (5b) to the second electrical component.
Connector (1) for connecting two electrical components according to claim 8, wherein
the connector (1) is a coaxial connector having one conductor (5) centrally disposed within the metal shell (2), or a differential pair connector having two conductors (5) that are electrically isolated from each other.
Connector (1) for connecting two electrical components according to claim 8 or 9, wherein
the metal shell (2) and/or the dielectric insulator (4) is or are intentionally provided with one or more structural weak points, such as notches (2c, 4c), cracks, or apertures, to facilitate achieving its or their bending.
Connector (1) for connecting two electrical components according to any one of claims 8 to 10, wherein
the dielectric insulator (4) is formed with an approximately X-shaped cross section.
Connector (1) for connecting two electrical components according to any one of claims 8 to 11, wherein
the dielectric insulator (4) consists of two identical dielectric insulator halves (4a), wherein, seen in cross section, a separation line between the dielectric insulator halves (4a) is parallel to a center axis of curvature of the curved metal tube (10), or

the dielectric insulator (4) consists of four identical dielectric insulator quarters (4b), wherein, seen in cross section, a first separation line between the dielectric insulator quarters (4b) is parallel and a second separation line between the dielectric insulator quarters (4b) is perpendicular to a center axis of curvature of the curved metal tube (10).
Connector (1) for connecting two electrical components according to any one of claims 8 to 12, wherein
the dielectric insulator (4) consists of a plurality of dielectric insulator disks (4d) arranged in succession in the longitudinal direction of the metal shell (2).
Printed circuit board assembly, comprising:
a printed circuit board as the first electrical component;

a printed circuit board header (3) on the printed circuit board;

at least one connector (1) according to any one of claims 8 to 13 installed into the printed circuit board header; and

the second electrical component plugged into the printed circuit board header (3).
Method of manufacturing a connector (1) for connecting two electrical components, comprising the steps of:
providing straight tube (7) made of metal;

bending the straight tube (7) into a curved tube (10) with a desired curved angle;

inserting at least one conductor (5) into a dielectric insulator (4); and

forming the connector (1) by inserting the dielectric insulator (4) with the at least one conductor (5) inserted therein into the curved tube (10).
Method of manufacturing a connector (1) for connecting two electrical components according to claim 15, further comprising the step of:
subjecting the dielectric insulator (4) to a preforming operation before inserting it into the curved tube (10) to obtain a preformed dielectric insulator (4e) having an angled shape approximately corresponding to that of the curved tube (10).
Method of manufacturing a connector (1) for connecting two electrical components, comprising the steps of:
providing a straight tube (7) made of metal;

inserting at least one conductor (5) into a dielectric insulator (4);

inserting the dielectric insulator (4) with the at least one conductor (5) inserted therein into the straight tube (7); and

bending the straight tube (7) as well as the dielectric insulator (4) and the at least one conductor (5) inserted therein to form a connector (1) having a curved tube (10) with a desired curved angle.