Abstract:
A cable connector and a manufacturing method thereof. The method includes: providing an insulation body, putting a terminal that has a receiving portion into the insulation body, preparing at least one groove on a cable, in which the cable has a first part inserted in the insulation body and a second part extending out of the insulation body, and the groove is provided on the first part, pressing the cable, so that a side edge of the receiving portion pierces the cable at the groove, thereby electrically connecting the terminal and an inner conductor of the cable. The groove enables the terminal to pierce the cable easily, implementing desirable electrical connection between the inner conductor and the terminal, and also stops the cable in the extending direction of the cable, preventing the cable from escaping.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 201210270648.1 filed in P.R. China on Aug. 1, 2012, the entire contents of which are hereby incorporated by reference. 
         [0002]    Some references, if any, which may include patents, patent applications and various publications, may be cited and discussed in the description of this invention. The citation and/or discussion of such references, if any, is provided merely to clarify the description of the present invention and is not an admission that any such reference is “prior art” to the invention described herein. All references listed, cited and/or discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference. 
       FIELD OF THE INVENTION 
       [0003]    The present invention relates generally to a cable connector and a manufacturing method thereof, and in particular, to a cable connector capable of firmly connecting a cable and a terminal, and a manufacturing method thereof. 
       BACKGROUND OF THE INVENTION 
       [0004]    A common radio frequency cable connector in the industry includes an insulation body. A receiving slot is provided in the insulation body. An insulation cover is disposed at a side of the receiving slot. A terminal is disposed in the insulation body. A shield shell wraps the insulation body. A coaxial cable is disposed in the receiving slot, and an inner conductor of the coaxial cable is electrically connected to the terminal. 
         [0005]    To ensure reliable electrical connection between the inner conductor and the terminal, in a conventional method, stripping is performed on the coaxial cable to expose the inner conductor, so that the inner conductor is soldered to the terminal. Such a manufacturing process in the method requires soldering, which adds steps to the entire manufacturing process, brings inconvenience to the manufacturing and assembly process, and increases the cost. 
         [0006]    In another method, the terminal has a main body portion in the shape of a flat plate. A side of the main body portion is bended and extended upward to form a press-contact portion. The entire terminal is bended and forms a clamp terminal. The inner conductor is disposed on the main body portion, and the insulation cover covers the press-contact portion. When the shield shell presses the insulation cover tightly, the insulation cover presses the press-contact portion, so that the press-contact portion presses the inner conductor against the main body portion, implementing electrical connection between the inner conductor and the terminal. Such a direct press-contact method makes the manufacturing process simple. However, the inner conductor is positioned only through press contact, a gap may exist between the main body portion and the press-contact portion, and the inner conductor may move between the two, affecting the electrical connection performance. In addition, the coaxial cable may be pulled when the cable connector is moved. The external periphery of coaxial cable is clamped by the shield shell, but the cable is not fixed in an extending direction. The coaxial cable may escape along an extending direction thereof from the insulation body and be disconnected from the terminal. 
         [0007]    In still another method, a piercing terminal is used. The cable is pressed when being put into the insulation body. A piercing portion of the terminal pierces an inner insulation layer of the cable and contacts the inner conductor. When a pressing force is applied to the cable, the piercing portion needs to pierce the inner insulation layer. If the force is too weak, the piercing portion cannot pierce the inner insulation layer, and the terminal fails to contact the cable. If the force is too strong, the terminal may be damaged. 
         [0008]    Therefore, a heretofore unaddressed need exists in the art to address the aforementioned deficiencies and inadequacies. 
       SUMMARY OF THE INVENTION 
       [0009]    In one aspect, the present invention is directed to a cable connector capable of firmly connecting a cable and a terminal, and a manufacturing method thereof. 
         [0010]    In one embodiment, a cable connector manufacturing method according to the present invention includes providing an insulation body, putting a terminal that has a receiving portion into the insulation body, preparing at least one groove on a cable, in which the cable has a first part inserted in the insulation body and a second part extending out of the insulation body, and the groove is provided on the first part, pressing the cable, so that a side edge of the receiving portion pierces the cable at the groove, and the terminal is electrically connected to an inner conductor of the cable. 
         [0011]    In one embodiment, stripping is performed on the cable before the groove is prepared on the cable, so that an inner insulation layer of the cable is exposed from an outer conductor and an outer insulation layer. 
         [0012]    In one embodiment, the cable is flattened to form at least one plane before the groove is prepared. 
         [0013]    In one embodiment, a shield shell is provided. The shield shell has a cylindrical portion and a plate portion connected to the cylindrical portion. The insulation body is put into the cylindrical portion. After the aforementioned step is completed, the plate portion is bended, so that the plate portion covers an opening of the cylindrical portion. 
         [0014]    In one embodiment, at least one locking piece is disposed on each of two sides of the plate portion. After the aforementioned step is completed, the locking piece is pressed by riveting to wrap the second part. 
         [0015]    In another aspect, the present invention is directed to a cable connector manufactured by using the above manufacturing method. The cable connector includes an insulation body that is provided with a receiving slot, a terminal disposed in the insulation body and having a receiving portion, and a cable having a first part and a second part, in which the first part is located in the receiving slot and the second part extends out of the insulation body. At least one groove is provided on the first part, the groove corresponds to the receiving portion, and the terminal is electrically connected to an inner conductor of the cable at the groove. 
         [0016]    In one embodiment, the cable is a coaxial cable, and includes the inner conductor, an inner insulation layer, an outer conductor and an outer insulation layer that are disposed from interior or exterior, and the groove is provided on the inner insulation layer. 
         [0017]    In one embodiment, the inner insulation layer at the groove is exposed from the outer conductor and the outer insulation layer. 
         [0018]    In one embodiment, the cable connector includes a shield shell. The shield shell includes a cylindrical portion and a plate portion connected to the cylindrical portion. The insulation body is received in the cylindrical portion, and the plate portion covers an opening of the cylindrical portion. 
         [0019]    In one embodiment, at least one locking piece is disposed at two sides of the plate portion, and the locking piece wraps the cable to fix the cable. 
         [0020]    In one embodiment, at least one extending portion is provided on the cylindrical portion along an extending direction of the cable, a dent is provided on the extending portion, and a protruding rib is provided on the locking piece and fits the dent for positioning. 
         [0021]    In one embodiment, at least one protruding block is provided on a side of the insulation body, and at least one concave portion is correspondingly provided at an edge of the cylindrical portion. The protruding block is stopped in the concave portion, to prevent the insulation body from falling off from the cylindrical portion. 
         [0022]    In one embodiment, the cable connector includes a second groove provided on the first part, the insulation body is provided with a limit portion, and the second groove is buckled with the limit portion, so as to prevent the cable from escaping. 
         [0023]    In one embodiment, at least one protruding portion is provided on a side wall of the receiving slot, and the protruding portion stops the cable, so as to prevent the cable from escaping in a direction opposite to an insertion direction thereof. 
         [0024]    In one embodiment, the terminal has a base portion. The receiving portion is provided on the base portion, and two clamp portions are provided at two sides of the receiving portion. When the cable is installed, the groove corresponds to the receiving portion, the clamp portions enter the groove, and a gap is provided between the clamp portion and an edge of the groove. 
         [0025]    In a further aspect, a cable connector includes an insulation body, in which the insulation body has a limit portion, a terminal disposed in the insulation body and having a receiving portion, and a cable having a first part and a second part, in which the first part is located in the insulation body and the second part extends out of the insulation body. At least two grooves are provided on the cable, at least one of the grooves is correspondingly buckled with the limit portion to maintain the cable in the insulation body, at least one of the grooves is provided corresponding to the receiving portion, and the terminal is electrically connected to the inner conductor of the cable at the groove. 
         [0026]    In one embodiment, a receiving slot is prepared on the insulation body along an extending direction of the cable. The first part is located in the receiving slot, at least one protruding portion is provided on a side surface of the receiving slot, and the protruding portion stops the cable, so as to prevent the cable from escaping in a direction opposite to an insertion direction thereof. 
         [0027]    In one embodiment, the cable connector includes a shield shell. The shield shell includes a cylindrical portion and a plate portion connected to the cylindrical portion. The insulation body is located in the cylindrical portion, and the plate portion covers an opening of the cylindrical portion. 
         [0028]    In one embodiment, at least one locking piece is disposed at two sides of the plate portion, and the locking piece wraps the cable to fix the cable. 
         [0029]    In one embodiment, at least one extending portion is provided on the cylindrical portion along an extending direction of the cable, a dent is provided on the extending portion, and a protruding rib is provided on the locking piece and fits the dent for positioning. 
         [0030]    Compared with the related art, among other things, the present invention has the following advantages. 
         [0031]    A groove is prepared on the cable. When the cable is pressed, a side edge of the receiving portion of the terminal pierces the cable at the groove, and the terminal is electrically connected to the inner conductor of the cable. The groove enables the terminal to pierce the cable easily, implementing desirable electrical connection between the inner conductor and the terminal, and also stops the cable in the extending direction of the cable, preventing the cable from escaping. 
         [0032]    These and other aspects of the present invention will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications therein may be effected without departing from the spirit and scope of the novel concepts of the disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0033]    The accompanying drawings illustrate one or more embodiments of the invention and together with the written description, serve to explain the principles of the invention. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein: 
           [0034]      FIG. 1  is a schematic exploded view of a cable connector according to one embodiment of the present invention; 
           [0035]      FIG. 2  is a schematic exploded view of an insulation body of a cable connector put into a cylindrical portion according to one embodiment of the present invention; 
           [0036]      FIG. 3  is a schematic three-dimensional view of a cable connector before a cover body thereof is bended according to one embodiment of the present invention; 
           [0037]      FIG. 4  is a schematic three-dimensional assembly view of a cable connector according to one embodiment the present invention; 
           [0038]      FIG. 5  is a cutaway top view of a part of a cable connector according to one embodiment of the present invention; and 
           [0039]      FIG. 6  is a three-dimensional cutaway view of a part of a cable connector according to one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0040]    The present invention is more particularly described in the following examples that are intended as illustrative only since numerous modifications and variations therein will be apparent to those skilled in the art. Various embodiments of the invention are now described in detail. Referring to the drawings, like numbers indicate like components throughout the views. As used in the description herein and throughout the claims that follow, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. Moreover, titles or subtitles may be used in the specification for the convenience of a reader, which shall have no influence on the scope of the present invention. 
         [0041]    As shown in  FIG. 1 , a cable connector  100  of the present invention includes a shield shell  1 , an insulation body  2 , a terminal  3 , and a cable  4 . 
         [0042]    As shown in  FIG. 1 , the shield shell  1  includes a cylindrical portion  11  and a plate portion  12 , and a connection portion  13  connects the plate portion  12  and the cylindrical portion  11 . The cylindrical portion  11  has a first opening  111  and a second opening  112  that are opposite to each other, and the second opening  112  is below the first opening  111 . The plate portion  12  can bend at the connection portion  13 , thereby covering the first opening  111 . Two concave portions  14  are provided at an edge of the first opening  111 , and are respectively located at two sides of the connection portion  13 . The cylindrical portion  11  is formed through rolling, and a joint of the roll is at a side opposite to the connection portion  13 . The cylindrical portion  11  extends at a side away from the connection portion  13  to form two extending portions  15 . A dent  151  is provided on the extending portion  15 . A pair of clamp portions  152  is formed at tails of the extending portions  15 . Multiple locking pieces  16  are disposed at two sides of the plate portion  12 , and include a pair of first locking pieces  161  and a pair of second locking pieces  162 . The locking pieces  16  can bend and wrap the cable  4 , thereby fixing the cable  4 . A protruding rib  1611  corresponding to the dent  151  on the extending portion  15  is provided on the first locking piece  161 . When the locking pieces  16  are pressed by riveting, the protruding rib  1611  fits the dent  151  for positioning. Multiple ribs  17  that protrude inward are further provided on the plate portion  12  and the second locking piece  162 . 
         [0043]    The insulation body  2  is received in the cylindrical portion  11 , and has a first main body portion  21  at a front end and a second main body portion  22  at a rear end. A first receiving slot  211  concavely extends downward from a top surface of the first main body portion  21 . A second receiving slot  221  concavely extends downward from a top surface of the second main body portion  22 . The first receiving slot  211  is in communication with the second receiving slot  221  to form a receiving slot  23  to receive the cable  4 . Two protruding blocks  24  are disposed at a front end of the first main body portion  21  and corresponding to the concave portions  14 . Two limit portions  25  are provided at a front end of the first receiving slot  211  and close to the protruding blocks  24 . Two stop portions  26  are further provided on side walls of the first receiving slot  211  in a protruding manner. A through hole  27  and a fixing slot  28  that are concaved downward are provided at the center of the first receiving slot  211 . The fixing slot  28  is near the through hole  27 , and the stop portions  26  are located above the through hole  27 . Two protruding portions  29  that protrude toward the interior of the second receiving slot  221  are provided on side walls of the second receiving slot  221 . The protruding portion  29  is wedge-shaped. 
         [0044]    The terminal  3  has a vertical base portion  31  that shapes like a plate. A receiving portion  32  is provided at the center of the base portion  31 . The receiving portion  32  is U-shaped. Two clamp portions  33  are formed at two sides of the receiving portion  32 , and two fixing portions  34  extend downward from the clamp portions  33 . The fixing portions  34  are fixed in the fixing slot  28 . The base portion  31  bends laterally to form two elastic arms  35  through extending. Two contact portions  36  are extended from middle portions of the elastic arms  35 . The contact portions  36  enter the through hole  27 . The elastic arms  35  are stopped by the stop portions  26 , preventing the terminal  3  from escaping. 
         [0045]    As shown in  FIGS. 1 and 5 , the cable  4  is a coaxial cable and includes an inner conductor  41 , an inner insulation layer  42 , an outer conductor  43 , and an outer insulation layer  44  that are disposed from interior to exterior. The cable  4  has a first part  45  and a second part  46 . The first part  45  is located in the insulation body  2 , and the second part  46  extends out of the insulation body  2 . The first part  45  only has the inner insulation layer  42  and the inner conductor  41 . A pair of first grooves  47  is provided on the inner insulation layer  42 . The first grooves  47  are provided corresponding to the receiving portion  32  of the terminal  3 . When the cable  4  enters the receiving portion  32 , the clamp portions  33  enter the first grooves  47 , pierce the inner insulation layer  42  at the grooves and contact the inner conductor  41 . A gap is provided between the clamp portion  33  and an edge of the first groove  47 , so that the clamp portion  33  enters the first groove  47  easily. A pair of second grooves  48  is further provided at a front end of the inner insulation layer  42 . The second grooves  48  are provided corresponding to the limit portions  25  of the insulation body  2 . When the cable  4  is put into the insulation body  2 , the second grooves  48  are buckled with the limit portions  25  to prevent the cable  4  from escaping along an extending direction thereof. The cable  4  has two opposite planes  49 . During preparation of the first grooves  47  and the second grooves  48 , the planes  49  have a positioning function. The first grooves  47  and the second grooves  48  are provided on cambered surfaces at side edges of the planes  49 . The first grooves  47  and the second grooves  48  are only provided on the inner insulation layer  42 , and do not completely penetrate the inner insulation layer  42 , so that the remaining inner insulation layer  42  protects the inner conductor  41 . 
         [0046]    A manufacturing method of the cable connector  100  is as follows: 
         [0047]    As shown in  FIG. 1 , at an initial state, the shield shell  1  is a metal plate. The cylindrical portion  11  is first formed by rolling. The plate portion  12  is connected to the cylindrical portion  11  and is in an open state. The plate portion  12  has an inclined angle relative to the cylindrical portion  11 . The locking pieces  16  at two sides of the plate portion  12  are flat. 
         [0048]    As shown in  FIG. 2 , the insulation body  2  is put downward into the cylindrical portion  11 . The two protruding blocks  24  at the front end are clamped in the two concave portions  14 . The second main body portion  22  is stopped at the edge of the first opening  111 . The three portions are used to stop the insulation body  2 , so as to prevent the insulation body  2  from falling off from the cylindrical portion  11 . The second main body portion  22  is clamped between the two extending portions  15 . 
         [0049]    As shown in  FIGS. 1-3 , the terminal  3  is put downward into the insulation body  2 . The contact portions  36  enter the through hole  27 . The fixing portion  34  is clamped in the fixing slot  28 . The elastic arms  35  cross the stop portions  26  and are stopped by the stop portions  26 , so that the terminal  3  does not escape in a direction opposite to the insertion direction thereof. 
         [0050]    The cable is flattened to form the two opposite planes  49 . In subsequent operations, the planes  49  are used to position the cable  4 . 
         [0051]    An automatic wire-stripping machine may be used to perform stripping on the cable  4 , so that only the inner insulation layer  42  and the inner conductor  41  remain at the first part  45  of the cable  4 , and the inner insulation layer  42  completely wraps the inner conductor  41 . The outer insulation layer  44 , close to the first part  45 , of the second part  46  is stripped off to expose the outer conductor  43 . 
         [0052]    As shown in  FIG. 1 , the first grooves  47  and the second grooves  48  are prepared on the inner insulation layer  42  of the first part  45 . The first grooves  47  and the second grooves  48  are prepared on the cambered surfaces of the side edges of the two planes  49 . The width of the first groove  47  is greater than the thickness of the base portion  31  of the terminal  3 . The first grooves  47  and the second grooves  48  are only provided on the inner insulation layer  42 , and do not completely penetrate the inner insulation layer  42 , so that the remaining inner insulation layer  42  protects the inner conductor  41 , avoiding damage to the inner conductor  41  during manufacturing. 
         [0053]    As shown in  FIGS. 3 and 5 , the cable  4  is pressed downward to be connected, so that the first grooves  47  are corresponding to the receiving portion  32 . The cable  4  crosses the protruding portions  29  and is stopped below the protruding portions  29 . The first part  45  enters the receiving slot  23 . The first grooves  47  are clamped in the receiving portion  32 . The two clamp portions  33  enter the first grooves  47 , pierce the inner insulation layer  42  on the side walls of the first grooves  47 , and contact the inner conductor  41 . A gap is provided between the clamp portion  33  and the edge of the first groove  47 , so that the clamp portion  33  enters the first groove  47  easily. The inner insulation layer  42  at the first groove  47  is thin, so a user can make the clamp portion  33  pierce the inner insulation layer  42  and be electrically connected to the inner conductor  41  with a small force. The terminal  3  is prevented from being damaged by an excessive force. The second grooves  48  enter the limit portions  25  in a clamped manner, and are buckled with the limit portions  25 , thereby limiting the movement of the cable  4  in the extending direction thereof. When the cable  4  is pulled, the second grooves  48  are buckled at the limit portions  25 , so that the cable  4  does not escape backward. The limit portions  25  stop the cable  4  in a vertical direction, preventing the cable  4  from escaping in a direction opposite to the insertion direction thereof. Meanwhile, the clamp portions  152  at the tail ends of the extending portions  15  clamp the outer conductor  43  of the second part  46 , thereby fixing the cable  4  to a degree. 
         [0054]    As shown in  FIGS. 3 and 4 , after the cable  4  is installed, the plate portion  12  is bended. The plate portion  12  covers the first opening  111 , the insulation body  2 , and an upper surface of the cable  4 , so that the insulation body  2  and the cable  4  do not escape from the cylindrical portion  11  in a direction opposite to the insertion direction thereof. The ribs  17  on the plate portion  12  press the cable  4 , enhancing retention of the cable  4  and the shield shell  1 . 
         [0055]    As shown in  FIG. 6 , finally, the locking pieces  16  are pressed by riveting, so that the locking pieces  16  are bended and wrap the cable  4 . The protruding rib  1611  on the first locking piece  161  is buckled with the dent  151  on the extending portion  15 , enhancing retention of the locking piece  16  and the extending portion  15 . The first locking piece  161  wraps a surface of the outer conductor  43 , and the second locking piece  162  wraps a surface of the outer insulation layer  44 , thereby fixing the cable  4 . Meanwhile, the ribs  17  on the locking pieces  16  urge against an outer surface of the cable  4 , so that the cable  4  and the locking pieces  16  are better fixed. 
         [0056]    In conclusion, the cable connector  100  of the present invention, among other things, has the following advantages. 
         [0057]    (1) The first groove  47  is prepared on the first part  45 . When the cable  4  is inserted into the insulation body  2 , the clamp portion  33  of the terminal  3  enters the first groove  47 , and pierces the inner insulation layer  42  at the first groove  47 , so as to be electrically connected to the inner conductor  41  of the cable  4 . The inner insulation layer  42  at the first groove  47  is thin, so a user can make the clamp portion  33  pierce the inner insulation layer  42  and be electrically connected to the inner conductor  41  with a small force. The terminal  3  is prevented from being damaged by an excessive force. 
         [0058]    (2) The second groove  48  is prepared on the cable  4 . When the cable  4  is inserted into the insulation body  2 , the second groove  48  enters the limit portion  25  in a clamped manner, and is buckled with the limit portion  25 , limiting the movement of the cable  4  in the extending direction thereof. When the cable  4  is pulled, the second groove  48  is buckled at the limit portion  25 , so that the cable  4  does not escape backward. 
         [0059]    The foregoing description of the exemplary embodiments of the invention has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching. 
         [0060]    The embodiments are chosen and described in order to explain the principles of the invention and their practical application so as to activate others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.