Electrical connector with center conductor

Patent metadata

Field	Value
Publication number	US-2021066873-A1
Application number	US-202017005315-A
Country	US
Kind code	A1
Filing date	Aug 28, 2020
Priority date	Aug 30, 2019
Publication date	Mar 4, 2021
Grant date	—

Abstract

A method of manufacturing an electrical connector includes: contacting an end portion of a center conductor exposed in an end portion of a coaxial cable having the center conductor with a conductive contact; applying ultrasonic vibration to the end portion of the center conductor and the contact to join the end portion of the center conductor and the contact each other; and accommodating the contact in an insulation housing after the end portion of the center conductor and the contact are joined to each other, and covering at least a part of a joint of the end portion of the center conductor and the contact with the insulation housing.

First claim

What is claimed is:

1 . A method of manufacturing an electrical connector comprising:
contacting an end portion of a center conductor exposed in an end portion of a coaxial cable having the center conductor with a conductive contact; applying ultrasonic vibration to the end portion of the center conductor and the contact to join the end portion of the center conductor and the contact to each other; and accommodating the contact in an insulation housing after the end portion of the center conductor and the contact are joined to each other, and covering at least a part of a joint of the end portion of the center conductor and the contact with the insulation housing.

2 . The method according to claim 1 , wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises:
sandwiching the end portion of the center conductor and the contact between a horn in contact with the end portion of the center conductor and an anvil in contact with the contact; and applying the ultrasonic vibration to the horn while the end portion of the center conductor and the contact are sandwiched between the horn and the anvil.

3 . The method according to claim 2 further comprising pressing the end portion of the center conductor and the contact by the horn and the anvil such that a cross section of the end portion of the center conductor is plastically deformed from a circular shape to a non-circular shape while the ultrasonic vibration is applied to the horn.

4 . The method according to claim 3 , wherein the contact has a joint surface,
wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises applying the ultrasonic vibration to the horn while the end portion of the center conductor is in contact with the joint surface and the anvil is in contact with a back surface of the joint surface, and wherein pressing the end portion of the center conductor and the contact comprises forming a formed joint surface along the joint surface on an outer peripheral surface of the end portion of the center conductor by pressing.

5 . The method according to claim 4 , wherein covering at least the part of the joint of the end portion of the center conductor and the contact with the insulation housing comprises covering the back surface of the joint surface with the insulation housing.

6 . The method according to claim 4 , wherein the horn has a pressing surface,
wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises applying the ultrasonic vibration to the horn while the pressing surface is in contact with the end portion of the center conductor, and wherein pressing the end portion of the center conductor and the contact comprises forming a formed outer surface along the pressing surface on the outer peripheral surface of the end portion of the center conductor by pressing.

7 . The method according to claim 6 , wherein the horn has a pressing groove and an inner surface of the pressing groove includes the pressing surface,
wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises applying the ultrasonic vibration to the horn while the end portion of the center conductor fits into the pressing groove, and wherein pressing the end portion of the center conductor and the contact comprises forming the formed outer surface along the inner surface of the pressing groove on the outer peripheral surface of the end portion of the center conductor by pressing.

8 . The method according to claim 7 , wherein the inner surface of the pressing groove has a first pressing surface and a second pressing surface that gradually approach each other toward a bottom of the pressing groove,
wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises applying the ultrasonic vibration to the horn while the outer peripheral surface of the end portion of the center conductor is in contact with the first pressing surface and the second pressing surface, and wherein pressing the end portion of the center conductor and the contact comprises forming the formed outer surface including a first formed outer surface along the first pressing surface and a second formed outer surface along the second pressing surface on the outer peripheral surface of the end portion of the center conductor by pressing.

9 . The method according to claim 4 , wherein the contact has a joint groove and an inner surface of the joint groove includes the joint surface,
wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises applying the ultrasonic vibration to the horn while the outer peripheral surface of the end portion of the center conductor is in contact with the inner surface of the joint groove, and wherein pressing the end portion of the center conductor and the contact comprises forming the formed joint surface along the inner surface of the joint groove on the outer peripheral surface of the end portion of the center conductor by pressing.

10 . The method according to claim 9 , wherein the joint surface includes a first joint surface and a second joint surface that gradually approach each other toward a bottom of the joint groove,
wherein applying the ultrasonic vibration to the end portion of the center conductor and the contact comprises applying the ultrasonic vibration to the horn while the outer peripheral surface of the end portion of the center conductor is in contact with the first joint surface and the second joint surface, and wherein pressing the end portion of the center conductor and the contact comprises forming the formed joint surface including a first formed joint surface along the first joint surface and a second formed joint surface along the second joint surface on the outer peripheral surface of the end portion of the center conductor by pressing.

11 . The method according to claim 10 , wherein the anvil has a supporting groove and an inner surface of the supporting groove includes a first supporting surface and a second supporting surface that gradually approach each other toward a bottom of the supporting groove, and
wherein pressing the end portion of the center conductor and the contact comprises pressing the end portion of the center conductor and the contact by the horn and the anvil while the first supporting surface faces a back surface of the first joint surface and the second supporting surface faces a back surface of the second joint surface.

12 . The method according to claim 4 , wherein accommodating the contact in the insulation housing and covering at least the part of the joint of the end portion of the center conductor and the contact with the insulation housing comprises press fitting the contact to the insulation housing.

13 . The method according to claim 12 , wherein the insulation housing has a cavity, and
wherein covering at least the part of the joint of the end portion of the center conductor and the contact with the insulation housing comprises accommodating the contact in the cavity of the insulation housing.

14 . The method according to claim 4 , wherein accommodating the contact in the insulation housing and covering at least the part of the joint of the end portion of the center conductor and the contact with the insulation housing comprises putting the contact into a mold and injecting a molten resin into the mold to mold the insulation housing.

15 . The method according to claim 14 , wherein injecting

Assignees

• I Pex Inc

Inventors

• Takao Hirofumi
• Hashimoto Yoichi
• Lin li yao

Classifications

• H01R13/6581

  Shield structure · CPC title

• H01R4/023

  between cables or wires and terminals · CPC title

• H01R24/40

  specially adapted for high frequency · CPC title

• H01R43/20

  for assembling or disassembling contact members with insulating base, case or sleeve · CPC title

• H01R13/405 Primary

  Securing in non-demountable manner, e.g. moulding, riveting · CPC title