Abstract:
A method of making a switch-equipped coaxial connector comprises the steps of stamping a pair of switching members from a metal sheet, bending the stamped switching members to complete the switching members, press-fitting the switching members into separate housing sections, assembling the housing sections so as to connect the switching members, and providing an outer conductor over said housing sections.

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     This is divisional application of prior application Ser. No. 09/398,004 file date Sep. 16, 1999 now U.S. Pat. No. 6,241,541. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to methods of making coaxial connectors equipped with a switch and, more specifically, to a switch-equipped coaxial connector comprising a hollow insulating housing, a switching mechanism provided within the insulating housing and comprising a pair of switching members, one of which is connected with a pin of a mating connector for connection while it is separated from the other, and an outer conductor provided over the insulating housing and connected to the outer conductor of a mating connector. 
     2. Description of the Related Art 
     Switch-equipped coaxial connectors are used for switching antennas. A switch-equipped coaxial connector is provided in a mobile phone or the like. When placed at a predetermined position in the car, the mobile phone is switched from the inside antenna to the outside antenna of the car. The dimensions of a usual switch-equipped coaxial connector are 3 mm in diameter and 6 mm in height. 
     A conventional switch-equipped coaxial connector is described in Japanese patent Kokai No. 8-167454. The coaxial connector comprises an insulating housing with a small hole and a switch mechanism press-fitted in the small hole. However, it is difficult to press-fit the switching mechanism into the small hole in addition to the following problems. 
     There are variations in the contact pressure and accuracy after the press-fitting. The switching mechanism is press-fitted while it is elastically deformed so that not only it is difficult to assemble but also it takes lots of time and cost. Also, it is necessary to use a complex jigs. The switch mechanism can be press-fitted obliquely, resulting in the lowered product quality. In addition, the mouth for receiving a mating pin tends to gather dust and dirt, presenting a problem of poor contact. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the invention to provide a method of making a switch-equipped coaxial connector which permits easier assembly with a shorter time at lower costs than before. 
     According to one aspect of the invention there is provided a method of making a switch-equipped coaxial connector, which comprises the steps of stamping a pair of switching members from a metal sheet; bending the stamped switching members to complete the switching members; press-fitting the switching members into separate housing sections; assembling the housing sections so as to connect the switching members; and providing an outer conductor over the housing sections. 
     According to another aspect of the invention there is provided a method of making a switch-equipped coaxial connector, which comprises the steps of simultaneously stamping a pair of switching members from a flat conductive sheet; bending the stamped switching members except for press-fit sections to complete the switching members; simultaneously press-fitting the switching members linked together into elongated cavity halves of respective housing sections linked together; severing the switching members from a carrier; assembling the housing sections to connect the switching members with a predetermined contact pressure; and providing an outer conductor over the housing sections. 
     According to one embodiment of the invention, the step of providing the outer conductor comprises covering the housing sections with the outer conductor so as to prevent separation of the housing sections. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a switch-equipped coaxial connector according to an embodiment of the invention; 
     FIG. 2 is a sectional view taken along line  2 — 2  of FIG. 1; 
     FIG. 3 is an exploded perspective view of the insulating housing and switching members fixed to the insulting housing; 
     FIG. 4 is a perspective view of a front portion of the second housing section after the first and second housing sections are assembled; and 
     FIGS.  5 ( a )-( c ) are schematic diagrams showing how to make the switch-equipped coaxial connector. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows a switch-equipped coaxial connector. FIG. 2 shows in section the coaxial connector into which a mating pin is inserted. The coaxial connector  1  comprises an insulating housing  20 , a switch mechanism  40 , and an outer conductor  50 . 
     The insulating housing  20  has a mouth section  21  through which a mating pin  5  is inserted and an elongated cavity section  22  for accommodating the mating pin  5 . The switching mechanism  40  extends along the elongated cavity  22  and switches circuits by the action of the mating pin  5 . It comprises a switching spring  40 A and a connection plate  40 B. The switching spring  40 A and the connection plate  40 B extend along the elongated cavity  22  or the insertion direction of the mating pin  5 . The switching spring  40 A and the connection plate  40 B are soldered to a board  3  at ends  48 A and  48 B, respectively. 
     The switching spring  40 A is normally displaced toward the connection plate  40 B. Consequently, before the mating pin  5  is inserted, the switching spring  40 A and the connection plate  40 B are connected to each other. The connection plate  40 B is fixed regardless of the mating pin  5  being inserted or not. 
     When the mating pin  5  is inserted in the elongated cavity  22 , the switching spring  40 A is brought into mechanical and electrical contact with the mating pin  5  and displaced away from the connection plate  40 B or in the direction perpendicular to the mating pin. A recess  23  is provided in the insulating housing to receive the front end  42 A of the switching spring  40 A. As best shown in FIG. 4, when the switching spring  40 A is displaced away from the connection plate  40 B, it is separated at a contact point  7  from the connection plate  40 B, thereby switching circuits. In FIG. 2, the circuits have been switched. By connecting the mating pin  5  to the outside antenna of a car and the connection plate  40 B to the inside antenna of a mobile phone it is possible to switch from the inside antenna to the outside antenna. When the mating pin  5  is removed from the elongated cavity  22 , the switching spring  40 A is displaced by its elastic force toward the connection plate  40 B, thereby making a contact with the connection plate  40 B. 
     The insulating housing  20  is covered by an outer conductor  50  which is separated electrically from the switching mechanism  40 . As best shown in FIG. 1, the outer conductor  50  is soldered to the board  3  as the switching spring  40 A and the connection plate  40 B. The outer conductor  50  and switching spring  40 A are fixed to the board  3  at right angles with each other, assuring stable attachment of the coaxial connector to the board. When plugged, the outer conductor  50  is connected to the outer terminal of a mating connector. Consequently, the coaxial connector and the mating connector are connected at two points between the outer conductor  50  and the outer conductor of the mating connector and between the switching spring  40 A and the mating pin  5 . 
     The structures of the housing and the switching mechanism will be described in more detail with reference to FIG. 3, wherein the switching mechanism is fixed in the insulating housing before assembling. 
     The insulating housing  20  is divided into two housing sections  20 A and  20 B. The insulating housing  20  may be divided into more sections. One of the advantages of division of the housing is an increase in design freedom. For example, it is impossible to provide the recess  23  (FIG. 2) unless the housing is divided. In this way, it is possible to mold the complicated inside structure of the insulating housing in a metal mold. Other advantages will be apparent from the following description. 
     The first and second housing sections  20 A and  20 B receive the switching spring  40 A and the connection plate  40 B, respectively. These housing sections are linked to each other by a linkage section  24  so that they are joined together accurately by turning one of them toward the other. The linkage section  24 , however, is not essential. A plurality of projections and indentations  25  are provided in the housing sections  20 A and  20 B to facilitate accurate assembling of the housing sections  20 A and  20 B into one body. 
     The switching spring  40 A is press-fitted into the first housing section  20 A before assembling by press-fitting the enlarged flat press-fit section  43 A into the press-fit slit  26 A of the first housing section  20 A so that the front portion of the switching spring  40 A is placed at a predetermined position in the elongated cavity  22 . The front portion of the switching spring  40 A is provided with a bend  41 A for contact with the mating pin  5 . The central portion  34  of the press-fit slit  26 A is removed so that the bend  41 A can pass through the slit  26 A without receiving a pressure. A contact section  44  extends upwardly from one of the edges of the bend  26 A. As best shown in FIG. 4, when the first and second housing sections  20 A and  20 B are assembled, the contact section  44  of the switching spring  40 A makes a contact with the connection plate  40 B at a point  7 . 
     The connection plate  40 B is press-fitted to the second housing section  20 B prior to assembling by press-fitting an enlarged flat press-fit section  43 B into a press-fit slit  26 B of the second housing section  20 B so that the front portion of the connection plate  40 B is placed at a predetermined position in the elongated cavity  22  of the second housing section  20 B. 
     As described above, the switching spring  40 A and the connection plate  40 B are press-fitted in the respective housing sections  20 A and  20 B prior to assembling. Consequently, it is not necessary to elastically deform the switching spring  40 A and the connection plate  40 B for fixing in the housing sections, making the complicated jigs unnecessary, the assembling easy, and the assembling time and cost reduced. In addition, there is no danger that the switching mechanism is press-fitted obliquely, keeping constant the contact pressure and accuracy between the switching spring  40 A and the connection plate  40 B, thus eliminating a cause of poor product quality. 
     A pair of flat members  45  and  46  extend upwardly from opposite sides of the elongated cavity  22  in the first housing section  20 A. When the first and second housing sections  20 A and  20 B are assembled, the flat members  45  and  46  are fitted into the corresponding areas in the elongated cavity  22  of the second housing section  20 B to secure the assembly of the first and second housing sections  20 A and  20 B. The larger flat member  45  also works as a pressure plate for holding down a front portion  47  of the connection plate  40 B. 
     A oblique surface  27  is provided in the second housing section  20 B to accommodate the contact section  44  of the switching spring  40 A when the first and second housing sections  20 A and  20 B are assembled. A cover projection  28  is provided on the second housing section  20 B to plug the central channel  34  of the first housing section  20 A to close the insulating housing  20  except for the mouth  21 . The airtight insulating housing  20  prevents a gas from entering the coaxial connector during soldering by reflow. Also, it permits transportation by vacuum suction of the insulating housing  20  in assembling. The edges of the cover projection  28  are tapered at  29  to facilitate smooth assembling of the housing sections  20 A and  20 B. Protruded portions may be provided on the side walls of the central channel  34  to improve the airtight quality of the insulating housing  20 . 
     The outer conductor  50  covers the housing sections  20 A and  20 B to prevent the separation thereof. A shoulder portion  30  is provided at a middle of the insulating housing  20  to temporarily hold the outer conductor  50 . Then, the outer conductor  50  is further pushed down to completely attach it to the insulating housing  20 . 
     Other examples of preventing separation of the insulating housing sections  20 A and  20 B include a lock device comprising a lock arm provided on one of the housing sections and a groove provided in the other housing section, the cover projection  28  press-fitted into the central channel  34  of the first housing section  20 A, and projections/indentations  25  press-fitted to each other. 
     FIG. 4 shows the front portion of the second housing section after assembling but before the mating pin is inserted. 
     A partition wall  31  extends from the mouth  21  into the elongated cavity  22  between the mouth  21  and the contact point  7  between the switching spring  40 A and the connection plate  40 B to prevent dust and dirt which have entered the elongated cavity through the mouth  21  from causing poor contact. No wall is provided an escape area  32  opposite to the partition wall  31  to permit escape of the dust and dirt which has entered the contact area between the switching spring  40 A and the connection plate  40 B. 
     The partition wall  31  also prevents the mating pin  5  from making contact with the connection plate  40 B. Also, it guides the front portion  47  of the connection plate  40 B when the connection plate  40 B is press-fitted into the second housing section  20 B. It is critical to accurately position the front portion  47  of the connection plate  40 B because it makes contact with the contact section  44  of the switching spring  40 A at the contact point  7 . Grooves may be provided in the partition wall  31  or the inside wall of the housing section  20 B to guide the front portion  47  to a predetermined position within the elongated cavity  22 . The partition wall  31  guides the contact section  44  of the switching spring  40 A to the connection plate  40 B to assure making the contact point  7  between the switching spring  40 A and the connection plate  40 B. Even if the switching spring  40 A is slightly deformed for some reason, the contact section  44  moves along the partition wall  31  to tolerate the deformation. The distance H between the partition wall  31  and the opposed wall  33  of the elongated cavity  22  is so large that if the switching spring  40 A is slightly displaced, there is provided a contact point between the switching spring  40 A and the connection plate  40 B. 
     How to make the switch-equipped coaxial connector will be described with reference to FIGS.  5 ( a )-( c ). As shown in FIG.  5 ( a ), a flat metal sheet  2  from a reel  9  is stamped to provide bodies of switching spring  40 A and the connection plate  40 B linked to a carrier. Then, the stamped bodies are bent to predetermined shapes to provide the switching spring  40 A and the connection plate  40 B. As shown in FIG.  5 ( b ), the switching members  40 A and  40 B are press-fitted into the elongated cavity halves  22 A and  22 B (FIG. 3) of the housing sections  20 A and  20 B through the slits  26 A and  26 B (FIG.  3 ). When the first and second housing sections are linked, the switching members  40 A and  40 B can be press-fitted in the housing at once. The connection plate  40 B is press-fitted in the press-fit slit  26 B along the partition wall  31  (FIG.  4 ). The switching spring  40 A and the connection plate  40 B are severed from the carrier after they are fixed to the housing sections  20 A and  20 B. Then, the housing sections  20 A and  20 B are assembled so that the switching spring  40 A is brought into contact with the connection plate  40 B with a predetermined pressure. Finally, as shown in FIG.  5 ( c ), the housing sections  20 A and  20 B are press-fitted into the outer conductor  50  to complete the switch-equipped coaxial connector. 
     Alternatively, the outer conductor may be replaced by a conductive plating provided on the housing. In this case, it is necessary to prevent separation of the housing sections by using the lock device or press-fit members. 
     Not only the switching spring  40 A but also the connection plate  40 B may be made movable by the insertion of the mating pin  5 . In this case, it is necessary to provide an insulation material on the connection plate at a contact point with the mating pin to prevent electrical connection. When the mating pin is inserted, the connection plate is brought into contact with the mating pin at the insulation material and displaced in the direction perpendicular to the insertion direction of the mating pin. 
     According to the invention, assembling of the switch-equipped coaxial connector is made easy, the manufacturing time and cost are reduced, and the precision of the switch mechanism is increased. In addition, dust and dirt hardly reach the contact point of the switching members.