IE54908B1

IE54908B1 - Electrical plug connector

Info

Publication number: IE54908B1
Application number: IE266383A
Authority: IE
Original assignee: Amp Inc
Priority date: 1982-11-17
Filing date: 1983-11-15
Publication date: 1990-03-14
Also published as: IE832663L; BR8306248A; DE3367141D1; MX159351A; EP0112019A1; CA1198789A; EP0112019B1

Abstract

An electrical plug connector comprises a slab-like dielectric contact-carrying member (36, 36A, 36B) having signal contact members (44, 44A, 102) secured to one side of the contact-carrying member (36, 36A, 36B) at spaced intervals therealong. A ground contact member (54, 54A, 120) is secured to the other side of the contact-carrying member (36, 36A, 36B) with contact sections (32, 34, 104, 122) of the signal contact members (44, 44A, 102) and the ground contact member (54, 54A, 120) extending from a front end of the contact-carrying member (36, 36A, 36B). Conductor-connecting sections (50, 60, 90, 92, 110, 128) of the signal and ground contact members extend along the contact-carrying member (36, 36A, 36B). Signal conductors (62) and ground conductors (66) of electrical cables (64) are electrically connected respectively to the conductor-connecting sections (50, 60, 90, 92, 110, 128) of the signal contact members (44, 44A, 102) and the ground contact member (54, 54A, 120). A dielectric housing member (72, 142) is secured onto the contact-carrying member (36, 36A, 36b) and part of the electrical cables (64) so that the contact members (44, 44A, 102, 54, 54A, 120) from their contact sections (32, 34, 104, 122) to their conductor-connecting sections (50, 60, 90, 92, 110, 128) are covered. [EP0112019A1]

Description

- 2 - - 2 -54908 This invention relates to electrical connectors and more particularly to an electrical plug connector in which electrical conductors of electrical cables are terminated to contact members and the terminations are sealingly 5 secured in a housing that supports the cables and is latchably mounted in a polarized position in a connector-receiving member.

Electrical connectors for transmission cables terminate the conductors of such cables. The connectors 10 are generally detachably connected to other electrical connectors for transmitting electrical signals from a transmission source to a receiving member or vice versa.

The connectors must be constructed to minimize losses or irregularities in the signals being transmitted from 15 the transmission source to the receiving member. The construction of the connectors must also be concerned with electrical performance characteristics so that they are not affected by wear and handling that results when equipment is moved and detachable connection and 2o reconnection with other connectors takes place.

US - A - 3 731 351 discloses an electrical plug connector of this type comprising an electrical contact assembly including a slab-like dielectric contact-carrying member on which signal and ground contact members are - 3 - - 3 - 54908 mounted at opposite sides, electrical cables having signal and ground conductors electrically connected respectively to conductor-connecting sections of the signal and ground contact members, and a dielectric housing on the electrical contact assembly.

It is an object of the present invention to provide an electrical plug connector of the type comprising an electrical contact assembly including a slab-like dielectric contact-carrying member on which signal and ground contact members are mounted at opposite sides, electrical cables having signal and ground conductors electrically connected respectively to conductorconnecting sections of the signal and ground contact members, and a dielectric housing on the electrical contact assembly, wherein mid sections of the signal contact members and a planar section of the ground contact member are secured to the contact-carrying member and signal and ground contact sections extend outwardly from a front surface of the contact-carrying member; said housing is overmolded securely and sealingly onto the contact assembly and sections of the electrical cables thereby spacing, supporting and providing strain relief for the cables the signal and ground contact sections extending downwardly from the front end of the housing.

In a plug connector conforming to the present invention, the housing member can have polarizing latching members that latch the plug connector in a polarized position in a connector-receiving member.

Figure 1 is a perspective and exploded view of an electrical connection system in which the invention is typically used, Figure 2 is a perspective and exploded view showing the parts of an electrical contact assembly of a connector, Figure 3 is a perspective view of Figure 2 in an assembled form, Figure 4 is a perspective view of the plug connector in a completed form.

Figure 5 is a cross-sectional view taken along line 5-5 of Figure 4, Figure 6 is a top plan view with parts broken away of the plug connector.

Figure 7 is a front elevational view of the plug connector, Figures 8 and 9 show parts of the connector and connector-receiving member illustrating the latching arrangement, Figure 10 is a view similar to Figure 2 showing the parts of an alternative embodiment of the electrical contact assembly. - 5 - - 5 - S 4 9 Ο 8 Figure 11 is a perspective view of Figure 10 in an assembled form, Figure 12 is a cross-sectional view along line 12-12 of Figure 11 with a housing secured on the contact assembly, Figure 13 is a view similar to Figures 2 and 10 showing the parts of a further embodiment of the electrical connector assembly.

Figures 14 and 15 are perspective views of Figure 13 in an assembled form, Figure 16 is a perspective view of the plug connector of Figures 13-15 in a completed form.

As shown in Figure 1, a multilayer circuit board 10 has areas 12 in which matrices of electrical receptacle contacts 14 are disposed. Connector-receiving members 16 are secured in position on board 10 via bolts 18. Spaced projections 20 are located along the inside surfaces of the tops and bottoms of members 16, forming channels in which slab-like electrical plug connectors 22 are latchably secured by flexible latch members 24 engaging surfaces 26 in openings 28 of members 16 as shown in Figures 8 and 9. This enables front sections of connectors 22 to be positioned through front openings 30 in members 16 so that tab contact sections 32 and 34 of connectors 22 can be electrically connected with - 6 - - 6 -54908 respective receptacle contacts 14 in areas 12.

Figures 2 through 9 illustrate electrical plug connector 22 ih greater detail. A slab-like contactcarrying member 36, moulded from a suitable dielectric 5 material has a series of three spaced recesses 38 located in one surface thereof. A pair of spaced circular projections 42 extends outwardly from the other surface of member 36.

Signal contact members 44 .are stamped and formed from 10 suitable sheet metal stock and they include contact sections 32, central sections 46 having oblong holes 48 therein, and conductor-connecting or ferrule sections 50. Each of contact sections 32 is folded back to provide a double layer of metal, the layers of which are maintained 15 in spaced relationship with one another by an inwardly- directed projection 52 formed in one layer. Central section 46 is planar and is disposed in a respective recess 38 of contact-carrying member 36 with oblong projection 40 extending through oblong hole 48. When 20 signal contact members 44 are secured in position in recesses 38 of contact-carrying member 36 via the outer ends of oblong projections 40 being enlarged by the application of pressure or heat, contact sections 32 extend outwardly from the front end of member 36 along the longitudinal axis thereof while conductor-connecting 25 - 7 - - 7 - 54908 sections 50 extend outwardly from the back end of member 36 along the same plane containing recesses 38. Sections of the contact member 44 between the contact section 32 and the central sections 46 are bent to position the 5 contact sections 32 generally in a medial plane of the slab-like member 36.

A ground contact member 54 has an elongated planar section 56 along which are disposed holes 58 for engagement with circular projections 42 when planar 10 section 56 is disposed against the bottom surface of contact-carrying member 36 whereafter the outer ends of projections 42 are enlarged by the application of pressure or heat thereby securing ground contact member 54 onto member 36. Adjacent the outer contact sections of the 15 series of signal contact sections 32, a pair of ground contact sections 34 extend outwardly from ground contact member 54, at one side, generally in the same manner as contact sections 32 and they have the same double layer configuration as contact sections 32 so that ground 20 contact sections 34 and are displaced from sections 56 to lie coplanar with contact sections 32. Four conductor-connecting sections 60 extend outwardly from planar section 56 at the other side of the ground contact member 54 and are spaced apart to extend outwardly from the back 25 end of member 36 in alternating spaced relationship with 8 respect to the section 50.

As can be discerned, when signal contact members 44 and ground contact member 54 are secured in position on contact-carrying member 36, an electrical contact assembly is formed with contact sections 32 and 34 disposed generally in a medial plane at the front end of contactcarrying member 36. Ground contact sections 34 are disposed adjacent the outer contact sections of the series of three signal contact sections 32. The arrangement of signal contact sections and ground contact sections can be in any manner as desired with ground contact sections 34 on each side of one or more signal contact sections 32 to make certain that optimum isolation of the signal information being processed along signal contact sections 32 is obtained.

Conductor-connecting sections 50 and 60 are laterally spaced with respect to one another in alternating manner as shown in Figure 3 and each conductor-connecting section 50 is centrally spaced with respect to conductorconnecting sections 60 on each side thereof as shown in Figures 3 and 6.

Contact-carrying members 36 spaces the signal contact members 44 relative to each other and relative to ground contact member 54.

Signal conductors 62 of three-load coaxial cables 64 - 9 - - 9 - 54908 are disposed in the respective conductor-connecting sections 50 of signal contact members 44 while ground or drain conductors 66 of each of cables 64 are disposed in respective conductor-connecting sections 60 immediately below and to each side of conductor-connection sections 50. Each cable 64 has a conductive coated plastic outer conductor surrounding the insulative sheath 68 covering signal conductors 62 which is electrically connected with a pair of drain conductors 66 thereby forming the three-lead coaxial cable 64 which also included outer dielectric jacket 70. Signal conducts 62 and drain conductors 66 are secured in conductor-connecting sections 50 and 60 in accordance with conventional crimping practices thereby terminating signal conductors 62 in respective conductorconnecting sections 50 of signal contact members 44 and drain conductors 66 in respective conductor-connecting sections 60 of ground contact member 54. As seen in Figure 3 the conductor-connecting sections 60 are in a modified figure eight configuration to position drain conductors 66 from adjacent cables therein. If desired, signal conductors 62 and drain conductors 66 can be electrically connected to conductor-connecting sections 50 and 60 respectively by the use of a laser to laser-weld the conductors to the conductor-connecting sections.

After conductors 62 and 66 of cables 64 have been - 10 - 10 54908 terminated to respective contact members 44 and 54, the terminated assembly is positioned in a mould which includes cable-positioning members so that dielectric housing 72 of suitable dielectric material may be moulded 5 onto contact-carrying member 36 including the parts of the signal and ground contacts secured thereto and the terminations of cables 64 to conductor-connecting sections 50 and 60. Openings 73 are formed in housing 72 due to the cable-positioning members. _ Housing 72 also covers 10 the inner parts of contact sections 32 and 34 as shown in Figure 5, and also covers sections of cables 64 to space and support them and provide strain relief therefor. Housing 72 also environmentally seals the terminations, stabilizes the contact sections and supports them.

The dielectric current constant of the material of contact-carrying member 36 and housing 72 is suitably substantially the same as that of the cables to maintain the integrity of the signals being transmitted along the cables and the contact members.

Flexible latch members 24 are integrally formed during the moulding of the housing 72 and each latch member includes a forward stop surface 74 which engages against an inside surface of connector-receiving member 16 as seen in Figure 9. Each of flexible latch members 24 25 includes a front leg 76 and a rear leg 78 converging - 11 - - 11 -54906 outwardly to a rear facing latch surface 80. The legs are flexed inwardly when plug 22 is inserted within connector-receiving member 16 being spaced projections 20. When stop surface 74 of latch members 24 engage the inside front surfaces of connector-receiving member 16, latch members 24 flex outwardly with front legs 76 extending into openings 28 to engage latching surfaces 80 with surfaces 26 thereby latchably securing plug connector 22 in position in connector-receiving member 16 as shown in Figure 9.

Arcuate projections 82 are located on housing 72 behind legs 76 and 78 to prevent latch members 24 from being overstressed when plug connectors 22 are moved into connector-receiving member 16. As shown in Figure 7, the latch member 24 at the left side is thicker than the latch member 24 on the right side and spaced projections 20 are accordingly spaced along connector-receiving member 16 thereby defining a polarizing arrangement to polarize the insertion of plug connectors 22 within connector-receiving member 16 to make certain that contact sections 32 and 34 are properly electrically connected with respective electrical receptacle contacts 14.

Whereas three-lead coaxial cables 64 have been disclosed as being terminated to the conductor-connecting sections of signal contact members 44 and ground contact - 12 - - 12 -5 4908 member 54 of the connector assembly, a three-lead transmission cable can also be used wherein a signal conductor is isolated from drain conductors on each side thereof. The typical assembly utilizing the present 5 invention is for ends of cables 64 or transmission cables to be terminated to electrical plug connectors 22 for transmitting electrical signals with high reliability and uniformity from a transmission source to a receiving member.

Figures 10 through 12 illustrate an alternative embodiment of the electrical contact assembly wherein contact-carrying member 36A includes a conductorpositioning section 84 along which are channels 86 and 88. Channels 86 are centrally aligned with recesses 38A in 15 which signal contact members 44A are secured via oblong projections 40A so that signal conductors 62 of cables 64 are positioned in channels 86 and in engagement with respective conductor-connecting sections 90 of signal contact members 44A which are engaged with conductor-20 positioning section 84. Ground conductors 66 and cables 64 are positioned along channels 88 on each side of a respective channel 86 and in engagement with a conductorconnecting section 92 of ground contact member 54A secured onto contact-carrying member 36A via projections 42A with 25 section 92 engaged with section 84. Conductors 62 and 66 - 13 - - 13 - 54908 are welded respectively to conductor-connecting sections 90 of contact members 44A and conductor-connecting section 92 of contact member 54A, preferably the laser-welding techniques. Housing 92A is molded onto the terminated contact assembly.

Figures 13-16 illustrate a further embodiment of the electrical contact assembly wherein contact-carrying member 36B includes conductor-positioning section 94 along which channels 96 are located in one side and channels 98 are located in the other side. Channels 96 are in communication with recesses 100 and both of channels 96 and 98 include beveled surfaces to guide signal conductors 62 and ground conductors 66 of cables 64 respectively along channels 96 and 98.

Signal contact members 102 are stamped and formed from pre-rolled or pre-milled metal stock with contact sections 104 being thicker than bent sections 106 which are thicker than central or mid sections 108 and ferrule sections 110. Hid sections 108, part of bent sections 106, and ferrule sections 110 of signal contact members 102 are disposed in respective recesses 100 with oblong projections 112 in recesses 100 extending through oblong holes 114 of mid sections 108 and ferrule sections being disposed between aligning projections 116 at the inner ends of recesses 100. Aligning projections 116 align - 14 - - 14 - 54908 ferrule sections 110 in recesses 100 so that slots 118 in ferrule sections 110 are in alignment with respective channels 96, slots 118 having a width slightly less than the diameter of signal conductors 62 so that they can be 5 force-fitted thereinto. After signal contact members 102 are positioned in recesses 100, projections 112 are mechanically or thermally deformed thereby securing contact members 102 in position with contact sections 104 extending outwardly from and being centrally aligned along 10 the front surface of contact-carrying member 36B.

Ground contact member 120 is stamped and formed from pre-rolled or pre-milled metal stock with contact sections 122 being thicker than bent sections 124 which are thicker than central section 126 which has a folded-over section 15 128 in which slots 130 are located. Slots 130 are in communication with respective openings 132 in bight section 134 which neck down as they merge with slots 130. The width of slots 130 is slightly smaller than the diameter of conductors 66 so that they can be force-fitted 20 thereinto.

Planar section 126 has holes 136 through which circular projections 138 on contact-carrying member 36B extend when ground contact member 120 is mounted thereon. Projections 138 are mechanically or thermally deformed thereby securing contact member 120 on member 36B with 25 - 15 - - 15 - 54908 contact sections 122 extending outwardly from and being centrally aligned along the front surface of member 36B so that contact sections 104 and 122 are in alignment.

Planar section 126 also has openings 140 therein which are 5 designed in size and location to tailor the impedance of the assembly to approximate the characteristic impedance of the cable.

After contact members 102 and 120 have been secured to member 36B, conductors 62 and 66 of cables 64 are 10 guided by channels 96 and 98 so as to be positioned along slots 118 and 130 of respective contact members 102 and 120. These conductors are then force-fitted into slots 118 and 130 whereafter they are laser welded in position in accordance with conventional welding practices thereby 15 forming the electrical contact assembly as shown in Figures 14 and 15.

Dielectric housing 142 as shown in Figure 16 is moulded onto the contact assembly in the same manner as that of housing 72 and housing 142 has a single opening 20 144 to minimize engagement with cables 64 to prevent distortion thereto. Integral flexible latch members 146 of different widths extend outwardly from the sides of housing 142 and arcuate projections 148, 150 are located on housing 142 and latch members 146 to prevent 25 overstressing of latch members 146. Housing 142 54908 - 16 - otherwise functions the same as housing 72 and the dielectric constant of the material of member 36B and housing 142 is substantially the same as that of cables 64 to maintain the integrity of the signals being transmitted along the cables and the plug member.

Claims

1. An electrical plug connector of the type comprising an electrical contact assembly including a slab-like dielectric contact-carrying member on which signal and ground contact members are mounted at opposite sides, electrical cables having signal and ground conductors electrically connected respectively to conductorconnecting sections of the signal and ground contact members, and a dielectric housing on the electrical contact assembly, wherein mid sections of the signal contact members and a planar section of the ground contact member are secured to the contact-carrying member and signal and ground contact sections extend outwardly from a front surface of the contact-carrying member; said housing is overmoulded securely and sealingly onto the contact assembly and sections of the electrical cables thereby spacing, supporting and providing strain relief for the cables the signal and ground contact sections extending downwardly from the front end of the housing.

2. An electrical plug connector as set forth in claim 1, wherein said signal contact sections and said ground contact sections are respectively arranged in generally coplanar fashion.

3. An electrical plug connector as set forth in Claim 1, wherein said conductor-connecting sections are ferrule 18 members which extend outwardly from a rear end of said contact-carrying member and in which the signal conductors and ground conductors are crimped and welded.

4. An electrical plug connector as set forth in Claim 1, wherein said conductor-connecting sections are planar sections disposed adjacent a conductor-positioning section of said contact-carrying member which has channels along which the signal conductors and ground conductors extend and are welded to said conductor-connecting sections.

5. An electrical plug connector as set forth in Claim 1, wherein said conductor-connecting sections of said signal contact members are ferrule members having slots therealong and said conductor-connecting section of said ground contact member is a planar member having slots, said ferrule members and said planar member disposed adjacent a conductor-positioning section of said contactcarrying member which has channels along which the signal conductors and ground conductors extend and which are positioned, in said slots and welded to said ferrule members and said planar member.

6. An electrical plug connector as set forth in Claim 1, wherein said contact-carrying member has oblong projections extending through oblong holes of the mid sections of the signal contact members, circular projections of the contact-carrying member extend through - 19 - - 19 - 54908 holes of the planar section of the ground contact member, outer ends of the oblong projections and the circular projections are distorted thereby securing the signal contact members and the ground contact members to the 5 contact-carrying member.

7. An electrical plug connector as set forth in Claim 1, wherein said signal contact sections and said ground contact sections are respectively formed by bent back metal layers.

8. An electrical plug connector as set forth in Claim 1, wherein said signal contact sections and said ground contact sections are solid stock.

9. An electrical plug connector as set forth in Claim 1, wherein the housing member has flexible latch members.

10. An electrical plug connector as set forth in Claim 9, wherein the latch members are of different widths.

11. An electrical plug connector, substantially as herein described with reference to and as shown in Figures 1 to 9 or Figures 10 to 12 or Figures 13 to 16 of the 20 accompanying drawings. MACLACHLAN & DONALDSON Applicants' Agents 47 Merrion Square Dublin 2.