Patent Publication Number: US-2004043674-A1

Title: DSX jack including contact

Description:
FIELD OF THE INVENTION  
       [0001] The present disclosure relates generally to conductive pins for electrical connectors and to methods for manufacturing such pins. More particularly, the present disclosure relates to center conductors for coaxial telecommunications connectors and t methods for manufacturing such conductors.  
       BACKGROUND  
       [0002] Coaxial connectors used in the telecommunications industry are typically provided with center conductors. An example center conductor  104  is shown in FIG. 14 of U.S. Pat. No. 5,417,588, which is hereby incorporated by reference in its entirety. The center conductor  104  is mounted in a dielectric housing  102  and includes a socket end  122  and a pin end  121 . The center conductor  104  is manufactured using a machining process (e.g., a drill or screw machine).  
       SUMMARY  
       [0003] The present disclosure relates to conductors for electrical connectors and to methods for making conductors for electrical conductors. It will be appreciated that the specific embodiments disclosed herein are examples of how the broad concepts of the present invention may be put into practice, and that variations can be made with respect to the described methods and conductors without departing from the broad scope of the present invention. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0004] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate examples of how certain inventions can be put into practice. A brief description of the drawings is as follows:  
     [0005]FIG. 1 is a front, left perspective view of a first center conductor that is an example of how certain aspects of the present invention can be put into practice;  
     [0006]FIG. 2 is a front view of the conductor of FIG. 1;  
     [0007]FIG. 3 is a left end view of the conductor of FIG. 2;  
     [0008]FIG. 4 is a right end view of the center conductor of FIG. 2;  
     [0009]FIG. 5 is a partial cross-sectional view of the center conductor of FIG. 1;  
     [0010]FIG. 6 illustrates a method for manufacturing the conductor of FIG. 1;  
     [0011]FIG. 7 illustrates a method for storing a plurality of the center conductors of FIG. 1;  
     [0012]FIG. 8 is a front, left perspective view of a second center conductor that is an example of how certain inventive aspects of the present disclosure can be put into practice;  
     [0013]FIG. 9 is a front view of the conductor of FIG. 8;  
     [0014]FIG. 10 is a top view of the center conductor of FIG. 9;  
     [0015]FIG. 11 is a bottom view of the center conductor of FIG. 9;  
     [0016]FIG. 12 is a left end view of the center conductor of FIG. 9;  
     [0017]FIG. 13 is a right end view of the center conductor of FIG. 9;  
     [0018]FIG. 14 is a plan view of a precursor center conductor prior to being rolled into the center conductor of FIG. 8;  
     [0019]FIG. 15 is a front, right perspective view of a third center conductor that is an example of how certain inventive aspects of the present disclosure can be put into practice;  
     [0020]FIG. 16 is a front view of the center conductor of FIG. 15;  
     [0021]FIG. 17 is a top view of the center conductor of FIG. 15;  
     [0022]FIG. 18 is a right end view of the center conductor of FIG. 15;  
     [0023]FIG. 19 is a plan view of a precursor center conductor prior to being rolled into the center conductor of FIG. 15;  
     [0024]FIG. 20 is a top view of a fourth center conductor that is an example of how certain inventive aspects of the present disclosure can be put into practice;  
     [0025]FIG. 21 is a cross-sectional view of the conductor of FIG. 20;  
     [0026]FIG. 22 is a left end view of the conductor of FIG. 20;  
     [0027]FIG. 23 is a right end view of the center conductor of FIG. 20;  
     [0028]FIG. 24 is a plan view of a precursor center conductor prior to being rolled into the center conductor of FIG. 20;  
     [0029]FIG. 25 is a front, right perspective view of a fifth center conductor that is an example of certain inventive aspects in accordance with the principles of the present invention;  
     [0030]FIG. 26 is a top view of the conductor of FIG. 25;  
     [0031]FIG. 27 is a front view of the center conductor of FIG. 25;  
     [0032]FIG. 28 is a right end view of the center conductor of FIG. 25;  
     [0033]FIG. 29 is a plan view of a precursor conductor prior to being rolled into the center conductor of FIG. 25;  
     [0034]FIG. 30 is a front, right perspective view of a sixth center conductor that is an example of how certain inventive aspects in accordance with the present disclosure can be put into practice;  
     [0035]FIG. 31 is a top view of the center conductor of FIG. 30;  
     [0036]FIG. 32 is a front view of the center conductor of FIG. 30;  
     [0037]FIG. 33 is a right end view of the center conductor of FIG. 30;  
     [0038]FIG. 34 is a left end view of the center conductor of FIG. 30;  
     [0039]FIG. 35 is a plan view of a precursor center conductor prior to being rolled into the center conductor of FIG. 30;  
     [0040]FIG. 36 is a front view of a seventh center conductor that is an example of how certain inventive aspects in accordance with the principles of the present disclosure can be put into practice;  
     [0041]FIG. 37 is a top view of the center conductor of FIG. 36;  
     [0042]FIG. 38 is a left end view of the center conductor of FIG. 36;  
     [0043]FIG. 39 is a right end view of the center conductor of FIG. 36; and  
     [0044]FIG. 40 is a plan view of a precursor center conductor prior to being rolled into the center conductor of FIG. 36.  
    
    
     DETAILED DESCRIPTION  
     [0045] FIGS.  1 - 5  illustrate a first center conductor  120  that is an example of how certain inventive aspects in accordance with the principles of the present disclosure can be put into practice. The center conductor  120  includes a socket end  122  positioned opposite from a pin end  124 . The socket end  122  defines an opening sized for receiving a pin of a coaxial connector. As shown schematically in FIG. 5, the interior  122   a  of the socket  122  is preferably coated with a conductive material such as a precious metal (e.g., gold). The socket end  122  also includes a contact tab  126  that is bent or otherwise deformed radially into the opening of the socket  122 . The tab  126  is adapted to assist in making contact with a pin of a coaxial connector inserted therein.  
     [0046] The pin end  124  of the conductor  120  is closed by tabs  128  (see FIG. 4). As best shown in FIG. 5, a portion  124   a  of the exterior surface of the pin  124  is coated or plated with a conductive material such as a precious metal (e.g., gold).  
     [0047] Referring to FIG. 2, the conductor  120  also includes a pair of retaining shoulders/beads  130 . The shoulders/beads  130  are positioned between the socket end  122  and the pin end  124  of the conductor  120 .  
     [0048] The conductor  120  is preferably manufactured by rolling a flat piece of material (i.e., a piece of stamped sheet metal) to form a hollow, cylindrical structure. After the rolling process, the edges of the piece of sheet metal oppose one another and define a seam  132  (see FIGS. 1 and 2) that extends axially along the entire length of the conductor  120 .  
     [0049] While the conductor  120  can be used in any number of different types of electrical connectors, a preferred use is in coaxial telecommunications connectors such as the connector disclosed in U.S. Pat. No. 5,417,588, which is hereby incorporated by reference.  
     [0050]FIG. 6 illustrates precursor center conductors  120 ′ in the process of being manufactured into the center conductor  120 . To manufacture the center conductor  120 , the precursor center conductors  120 ′ are stamped, cut or otherwise provided from a piece of sheet metal. Each precursor conductor  120 ′ includes a precursor socket portion  122 ′ and precursor pin portion  124 ′. The precursor socket portion  122 ′ has a greater width W1 than a corresponding width W2 of the precursor pin portion  124 ′. Structures are stamped, cut or otherwise provided in the precursor conductors  120 ′ while the precursor structures  120 ′ are flat. For example, slits  140  are provided in the precursor socket portions  122 ′ so as to define precursor tab portions  126 ′. Additionally, precursor tab portions  128 ′ are provided at the precursor pin end  124 ′. Moreover, precursor shoulders/beads  130 ′ are also stamped, pressed or otherwise formed on the precursor conductor  120 ′.  
     [0051] After the various structures have been provided on the precursor conductor  120 ′, the precursor conductor  120 ′ is rolled into a cylinder as shown in FIG. 6. Additionally, the precursor tabs  128 ′ are bent to close the end of the pin portion  124 , and the precursor tab  126 ′ is bent radially inward into the socket portion  122 . It will be appreciated that the various wrapping/rolling, and bending or deforming steps can be made in multiple steps along an assembly line. Additionally, prior to rolling the center conductors  120 , a front side of the precursor socket portion  122 ′ is coated/plated with a precious metal, and a back side of the precursor pin portion  124 ′ is coated/plated with a precious metal. To conserve precious metals, only the tip region of the precursor pin portion  124 ′ is plated with the precious metal. The remainder of the back side of the precursor conductor  120 ′ is not coated with precious metal. Similarly, on the front side of the precursor conductor  120 ′, only the precursor socket portion  122 ′ is plated with the precious metal.  
     [0052] Referring still to FIG. 6, a plurality of the precursor conductors  120 ′ and conductors  120  are shown connected to an index strip  150  by breakaway connections. The index strip  150  has openings  152  which correspond to the spacing of the conductors  120  and the precursor conductors  120 ′. The openings  152  facilitate automatically handling of the strip by assembly line equipment. The strip  150  also facilitates storage of the conductors  120  by allowing the conductors  120  to be wrapped in a roll  154  as shown in FIG. 7. Preferably, paper  156  is provided between each wrap of the roll to protect the conductors  120 .  
     [0053] FIGS.  8 - 13  illustrate a second center conductor  220  that is an example of certain inventive aspects in accordance with the principles of the present disclosure. The conductor  220  includes a socket end  222  and a pin end  224 . The socket end defines an opening  223  for receiving a pin. The socket end  222  also includes a contact tab  226 . The contact tab  226  extends in a circumferential direction about a longitudinal axis of the conductor  220 . The socket end  220  also includes an indent  229  (shown in FIG. 12) that projects into the opening  223  of the socket. As shown in FIG. 12, the indent  229  is positioned opposite from the circumferential tab  226 . The conductor  220  includes a seam  221  (see FIGS.  11 - 13 ) that extends longitudinally along a length of the conductor  220 .  
     [0054] The center conductor  220  is preferably made by rolling a generally flat precursor conduit such as the precursor conduit  220 ′ shown in FIG. 14. The precursor conduit  220 ′ includes a precursor socket portion  222 ′ and a precursor pin portion  224 ′. A precursor tab  226 ′ is cut in the precursor socket structure  222 ′. The precursor tab  226 ′ extends in a direction transverse with respect to a longitudinal axis  225  of the precursor conductor  220 ′. A precursor indent  229 ′ is also provided in the precursor socket portion  222 ′ by conventional techniques such as punching or stamping.  
     [0055] The conductor  220  is made by rolling the precursor conductor  220 ′ into a cylinder. The precursor tab portion  226 ′ is then bent at a smaller radius than the curvature of the socket portion  222  such that the tab  226  projects into the opening  223  of the socket  224 . Prior to rolling the precursor conductor  220 ′, the precursor conductor  220 ′ can be plated with a precious metal as previously described with respect to the first embodiment.  
     [0056] FIGS.  15 - 18  show a third center conductor  320  that is an example of certain inventive aspects in accordance with the principles of the present disclosure. The conductor  320  includes a socket  322  and a pin  324 . The socket  322  includes an opening  323  for receiving a pin. The socket  322  also includes a contact tab  326  that projects into the opening  323 . The contact tab  326  has a free end  327  that is bent radially inwardly into the opening  323  in a hook-like configuration (see FIG. 16). A seam  321  extends along the length of the conductor  320 .  
     [0057] The conductor  320  is preferably manufactured by initially providing a planar, precursor conductor such as precursor conductor  320 ′ shown in FIG. 19. The precursor conductor  320 ′ includes a precursor socket portion  322 ′ and a precursor pin portion  324 ′. The precursor socket portion  322 ′ has been cut so as to define a precursor contact tab  326 ′. The conductor  320  can be manufactured by rolling the precursor conductor  320 ′ into a cylinder, and by deforming the precursor contact tab  326 ′ radially inwardly. Similar to the other embodiments, selected portions of the precursor conductor  320 ′ can be plated with a precious metal conductor prior to the rolling process.  
     [0058] FIGS.  20 - 23  illustrate a fourth center conductor  420  that is an example of how certain inventive aspects in accordance with the principles of the present disclosure can be put into practice. The conductor  420  includes a socket portion  422 , a pin portion  424 , and an intermediate portion  425  positioned between the socket portion  422  and the pin portion  424 . The intermediate portion  425  has a diameter that is larger than the diameter of the pin portion  424  and smaller than the diameter of the socket portion  422 . The socket portion includes a central opening  423  for receiving a pin, and a contact  426  that projects into the opening  423 . The contact  426  has a cantilevered configuration. The contact  426  is bent radially inwardly at its base end so as to project into the opening  423 . A free end  427  of the contact  426  curves radially outwardly (see FIG. 21).  
     [0059] Referring still to FIGS.  20 - 23 , two shoulders  431  are provided on the intermediate portion  425  of the conductor  420 . Additionally, the conductor  420  defines a seam  433  positioned opposite from the contact  426 .  
     [0060]FIG. 24 is a plan view of a precursor conductor  420 ′ that is rolled from its planar form to provide the conductor  420 . The precursor conductor  420 ′ includes a precursor socket portion  422 ′, a precursor pin portion  424 ′, and a precursor intermediate portion  425 ′. Precursor shoulders  431 ′ are provided on the precursor intermediate portion  425 ′. Additionally, the precursor socket portion  422 ′ is cut, slit stamped or otherwise provided with openings that define a precursor contact  426 ′.  
     [0061] To manufacture the conductor  420 , the precursor conductor  420 ′ is plated at selected regions with a conductor such as a precious metal, and then rolled into a cylindrical configuration. After rolling the precursor conductor  420 ′ into a cylinder, the precursor contact  426 ′ is deformed radially inwardly so as to define the contact  426 .  
     [0062] FIGS.  25 - 28  depict a fifth conductor  520  that is an example of how certain inventive aspects in accordance with the principles of the present invention may be practiced. The conductor  520  includes a socket portion  522  and a pin portion  524 . The socket portion  524  defines a central opening  523  adapted for receiving a contact pin of another connector. The socket  522  includes opposing contacts  526  aligned at acute angles relative to one another. The contacts  526  are integral with the socket portion  522  at a location opposite from a longitudinal seam  531  of the conductor  520 .  
     [0063] Similar to the previous embodiments, the conductor  520  is preferably manufactured using a rolling processing in which a flat precursor conductor is rolled into the shape of FIGS.  25 - 28  during one or more rolling/forming steps. FIG. 29 depicts an exemplary planar, precursor conductor  520 ′ adapted for manufacturing of a conductor  520 . The precursor conductor  520 ′ includes a precursor socket portion  522 ′ and a precursor pin portion  524 ′. Openings are provided in the precursor socket portion  522 ′ (e.g., by a process such as cutting, stamping or pressing). The openings define precursor contacts  526  on the precursor socket portion  522 ′. The contacts  526  have a V-shaped configuration. As shown in FIG. 28, the contacts  528  extend in a chord-like manner across the opening  523  of the socket  522 .  
     [0064] To manufacture the conductor  520 , selected regions of the precursor conductor  520 ′ are plated with a material such as a precious metal, and the precursor conductor  520 ′ is then rolled into a generally cylindrical shape as shown in FIGS.  25 - 28  by one or more rolling steps. Thereafter, the contacts  526  can be plastically deformed so as to assume the positions depicted in FIGS.  25 - 28 .  
     [0065] FIGS.  30 - 34  depict a sixth conductor  620  that is an example of certain inventive concepts in accordance with the principles of the present disclosure. The conductor  620  includes a socket portion  622  and a pin portion  624 . The socket portion  622  defines a central opening  623  adapted for receiving a conductive pin of another connector. An open region  637  is defined through the socket portion  522 . Two opposing contacts  626  project into the opening  523 . The contacts  626  have base ends  627  and free ends  629 . The contacts  626  are aligned at oblique angles relative to one another and converge towards one another as the contacts extend toward the pin portion  624  (see FIG. 31).  
     [0066] Similar to the previous embodiments, the conductor  620  can be manufactured by using a rolling process to form a planar precursor conductor into a cylindrical shape. FIG. 35 depicts a precursor conductor  620 ′ suitable for manufacturing the conductor  620 . The precursor conductor  620 ′ includes a precursor socket  622 ′ and a precursor pin  624 ′. A portion of the precursor socket  622 ′ has been removed so as to define two precursor contacts  626 ′. To manufacture the conductor, the precursor conductor  520 ′ is rolled to the configuration of FIGS.  30 - 34 . Thereafter, the precursor contacts  626 ′ are deformed radially inwardly to match the configuration best shown in FIG. 31. Similar to previous embodiments, selected regions of the precursor conductor  620 ′ can be plated with a metal material such as a precious metal.  
     [0067] FIGS.  36 - 39  illustrate a seventh conductor  720  that is an example of how certain inventive aspects in accordance with the principles of the present disclosure can be put into practice. The conductor  720  includes a socket portion  722  and a pin portion  724 . An opening  740  has been cut or otherwise provided in the side wall of the socket portion  722 . A contact  726  projects through the opening into the interior of the socket  722 . The contact  726  has a base end  727  connected to the socket wall and a free end  729  that projects into the interior of the socket  722 .  
     [0068] Similar to the previous embodiments, the conductor  720  can be manufactured by rolling or otherwise forming a flat, precursor structure into a cylindrical conductor. FIG. 40 illustrates an example precursor conductor  720 ′ adapted for making the conductor of FIGS.  36 - 39 . The precursor conductor  720 ′ includes a precursor socket wall  722 ′ and a precursor pin  724 ′. A portion of the precursor socket wall  722 ′ has been removed so as to provide a precursor contact  726 ′ having a base end connected to the precursor socket wall  722 ′ and an unattached free end. The conductor  720  is manufactured by rolling or otherwise forming the precursor conductor  720 ′ into a generally cylindrical configuration. Thereafter, the precursor contact  726 ′ can be inelastically deformed through the opening in the socket wall and into the pin receptacle of the socket portion  722 . Prior to rolling the precursor conductor  720 ′, a metal such as a precious metal can be plated on selected regions of the precursor socket wall  722 ′ and the precursor pin wall  724 ′. The contact  726  is oriented such that its free end is closer to the conductor pin  724  than its base end.  
     [0069] It will be appreciated that the embodiments disclosed herein are merely examples, and that variations can be made without departing from the broad inventive scope of the present disclosure.  
     [0070] While it is preferred for a rolling process to be used to manufacture the various conductors disclosed herein, it will be appreciated that for at least certain embodiments, other manufacturing techniques such as machinings could also be used. Further, in certain non-limiting embodiments, the planar precursor conductors can be made of a sheet metal material such as phosphorous bronze or beryllium copper.