Patent Publication Number: US-2023143087-A1

Title: Connector assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims benefit of priority to European Patent Application No. 21207596.4 filed on Dec. 9, 2021, and European Patent Application No. 21213495.1 filed on Nov. 10, 2021, the entire disclosure of each of which is hereby incorporated by reference. 
     TECHNICAL FIELD OF THE INVENTION 
     The present disclosure relates to a connector assembly, preferably for multi GHz applications. In particular, the disclosure relates to a high speed twisted pair data connector assembly. 
     BACKGROUND 
     High speed twisted pair data cables may be used for automotive 4K camera systems, autonomous driving, RADAR, LIDAR, high-resolution displays and rear seat entertainment. The connectors of these cables may be configured to allow data transmission up to 15 GHz or 20 Gbps while providing a small package size. 
     In such high-speed applications, every tenth of a millimeter of the interconnection channel and of the signal connectors should be within a certain data transmission (differential) impedance bandwidth (typically 100±5Ω) and should be matched to preceding and succeeding sections. To this end, in each of these sections, metal portions of an inner contact or signal contact and an outer contact or shielding, insulating material of an insulating element and any air gaps must be balanced in size and position with respect to each other. However, there is also a need for these components to meet other non-signal-integrity requirements, in particular mechanical requirements. For example, it has to be ensured that a male signal contact is always correctly guided into a corresponding female signal contact. To achieve high data transmission, an optimum electrical and mechanical connection between a male signal contact and a female signal contact is indispensable. Accordingly, there is a need to provide a connector assembly of high speed twisted pair data cables that enables a more accurate connection between male and female signal contacts. 
     SUMMARY 
     In one aspect, the present disclosure is directed at a connector assembly. The connector assembly includes at least one elongated inner signal contact having a first connection portion. The first connection portion includes a tube-like main section and a funnel-shaped end section; and an insulating element. The insulating element defines at least one elongated cavity designed to accommodate the elongated inner signal contact. A maximum outer cross-sectional dimension of the funnel-shaped end section is greater than a minimum cross-sectional dimension of the elongated cavity. 
     The connector assembly may be configured for high speed data transmission. In particular, the connector assembly may be for high speed twisted pair data cables in automotive applications. 
     The connector assembly described herein is a female connector assembly, i.e., the inner signal contact is a female signal contact. The inner signal contact has a funnel-shaped end section allowing for pin movement, i.e., allowing insertion of a male signal contact pin. 
     The inner signal contact is embedded in an insulating element which may form a one-part housing or a multi-part housing, in particular a two-part housing. More specifically, the insulating element may define a cavity having a first cavity portion which receives the tube-like main section of the inner signal contact, and a second cavity portion which receives the funnel-shaped end section of the inner signal contact. A cross-sectional dimension of the first cavity portion, also referred to as a minimum cross-sectional dimension of the cavity, and an outer cross-sectional dimension of the tube-like main section may be substantially equal, i.e., the tube-like main section may be embedded in the first cavity portion with marginal clearance between the tube-like main section and the insulating material defining the first cavity portion. 
     Since the inner signal contact expands or flares in a direction away from the tube-like main section to form the funnel-shaped end section, a maximum outer cross-sectional dimension of the funnel-shaped end section is greater than the outer cross-sectional dimension of the tube-like main section. Consequently, the maximum outer cross-sectional dimension of the funnel-shaped end section is also greater than the cross-sectional dimension of the first cavity portion, i.e., the minimum cross-sectional dimension of the cavity, thereby making it generally impossible for the inner signal contact to be pushed along the length of the cavity. 
     It is to be understood that in order to be able to accommodate the funnel-shaped end section of the inner signal contact, the cross-sectional dimension of the second cavity portion, also referred to as a maximum cross-sectional dimension of the cavity, must at least correspond to the maximum outer cross-sectional dimension of the funnel-shaped end section and as such is also greater than the minimum cross-sectional dimension of the cavity. 
     According to an embodiment, the funnel-shaped end section may include a first end section part and a second end section part. The first end section part and the second end section part are separated by two air gaps. The air gaps may be diagonally arranged, i.e., the two air gaps are arranged opposite from each other. The first end section and the second end section of the funnel-shaped end section allow a spreading apart of the funnel-shaped end section to thereby make the insertion of a male signal contact pin easier. According to another embodiment, the funnel-shaped end section may be a machined end section or a stamped, rolled, or bent end section, in which a first end section part and a second end section part are separated by just one small slit. 
     According to an embodiment, the insulating element may include at least one front opening configured to receive the funnel-shaped end section, and two chamfers protruding into the air gaps such that the first end section part, the second end section part and the two chamfers define an inlet. In other words, the chamfers may radially protrude into the front opening. The two chamfers may be arranged diagonally to each other. 
     The front opening of the insulating element may be configured to receive a male signal contact, and the inlet serves to lead the male signal contact into the female inner signal contact of the connector assembly. The inlet may provide an at least approximately 360° lead-in cone to guide the male signal contact into the tube-like main section of the female inner signal contact. Thus, an incorrect connection of the signal contacts can be prevented which may occur by inserting the male signal contact past the inner signal contact. Furthermore, damage to at least one of the male signal contact, the inner signal contact and the insulating element may be avoided. 
     According to an embodiment, the funnel-shaped end section includes a first end section part and a second end section part. The first end section part and the second end section part are separated by two air gaps. The insulating element includes at least one rib engaging one of the air gaps and thereby widening the funnel-shaped end section. the size of the inlet may be maximized by widening the funnel-shaped end section. The two air gaps may be arranged diagonally to each other. 
     According to an embodiment, the insulating element and the at least one elongated inner signal contact may include at least one protrusion and at least one recess, respectively. The protrusion and the recess are configured to cooperate in order to at least reduce or even prevent a rotation and/or an axial movement of the at least one elongated inner signal contact relative to the insulating element. The at least one protrusion may be a blocking element that provides a forward stop and/or a backward stop for the at least one elongated inner signal contact in the insulating element. A precise rotational control and limitation of movement of the inner signal contact as well as a precise rigid back and forward stop of the inner signal contact may thus be achieved. 
     According to an embodiment, the insulating element may include a control element and the at least one elongated inner signal contact may include a hole receiving the control element when the connector assembly is correctly assembled. The control element may be visible in the hole of the at least one elongated inner signal contact when the at least one elongated inner signal contact reaches its correct end-position during assembling. Thus, easy visual confirmation of a correct assembly of the at least one elongated inner signal contact in the insulating element is possible. 
     According to an embodiment, the insulating element may include at least one clamping element configured to secure a wire to which the at least one elongated inner signal contact is connected. 
     According to an embodiment, the at least one elongated inner signal contact may include a termination element configured to receive a wire and the insulating element may include at least one retaining element configured to secure the termination element and/or the wire in the insulating element. The termination element may include a pair of crimping wings or any other suitable termination means. 
     According to another embodiment, the insulating element may include a first insulating part and a second insulating part. The first insulating part and the second insulating part surround the at least one inner signal contact. The terms “first” and “second” are only used to differentiate the two insulation parts. There is no restriction to features concerning the first insulating part or the second insulating part, i.e., all features of the first insulating part may also be features of the second insulating part. 
     According to an embodiment, one of the first insulating part and the second insulating part may be configured to be radially mounted in respect of the at least one elongated inner signal contact and the respective other one of the first insulating part and the second insulating part is configured to be axially slid onto the at least one elongated inner signal contact. 
     According to an embodiment, the at least one elongated inner signal contact may be pinched into the first insulating part or the second insulating part. 
     According to an embodiment, the first insulating part or the second insulating part may include a press fit element configured to secure the first insulating part to the second insulating part. 
     According to an embodiment, the first insulating part or the second insulating part may include at least one locking element configured to snap fit the first insulating part and the second insulating part together and thereby secure the first insulating part to the second insulating part. The locking element may provide a passive lock and/or an active lock. 
     According to an embodiment, the first insulating part or the second insulating part may include a pin and the respective other one of the first insulating part and the second insulating part includes a slot. The slot is configured to receive the pin and the pin is deformed and secured in the slot to thereby secure the first insulating part to the second insulating part. 
     According to an embodiment, the first insulating part or the second insulating part may include a groove and the respective other one of the first insulating part and the second insulating part may include a tongue received in the groove. 
     According to an embodiment, the first insulating part or the second insulating part may include a locking cavity and the respective other one of the first insulating part and the second insulating part may include a locking protrusion received in the locking cavity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is now described, by way of example with reference to the accompanying drawings, in which: 
         FIG.  1    shows an exploded view of a connector according to an embodiment; 
         FIG.  2 A  shows an isometric view of a connector assembly according to an embodiment; 
         FIG.  2 B  shows an exploded view of the connector assembly of  FIG.  2 A  according to an embodiment; 
         FIG.  3 A  shows an isometric view of inner signal contacts according to an embodiment; 
         FIG.  3 B  shows an isometric view of inner signal contacts according to another embodiment; 
         FIG.  3 C  shows an isometric view of inner signal contacts according to another embodiment; 
         FIG.  4 A  shows a cross-sectional view of the connector assembly in a partly assembled state according to an embodiment; 
         FIG.  4 B  shows a cross-sectional view of the connector assembly in a fully assembled state according to an embodiment; 
         FIG.  5 A  shows an isometric view of a funnel-shaped end section of an inner signal contact according to an embodiment; 
         FIG.  5 B  shows a cross-sectional view of the funnel-shaped end section according to an embodiment; 
         FIG.  6 A  shows an isometric view of front openings of an insulating element according to an embodiment; 
         FIG.  6 B  shows a front view of the front openings having inner signal contacts according to an embodiment; 
         FIG.  6 C  shows a front view of an inlet opening defined by the inner signal contacts according to an embodiment; 
         FIG.  7 A  shows an isometric view of a part of an insulating element having inner signal contacts in a partly assembled state according to an embodiment; 
         FIG.  7 B  shows a cross-sectional view of the part of the insulating element having the inner signal contacts in the partly assembled state according to an embodiment; 
         FIG.  7 C  shows an isometric view of the part of the insulating element having inner signal contacts in a fully assembled state according to an embodiment; 
         FIG.  7 D  shows a cross-sectional view of the part of the insulating element having inner signal contacts in the fully assembled state according to an embodiment; 
         FIG.  8 A  shows a cross-sectional top view of a connector assembly according to an embodiment; 
         FIG.  8 B  shows a cross-sectional side view of the connector assembly of  FIG.  8 A  according to an embodiment; 
         FIG.  8 C  shows a cross-sectional top view of a connector assembly according to an embodiment; 
         FIG.  8 D  shows a cross-sectional side view of the connector assembly of  FIG.  8 C  according to an embodiment; 
         FIG.  8 E  shows a cross-sectional top view of a connector assembly according to an embodiment; 
         FIG.  8 F  according to an embodiment a cross-sectional side view of the connector assembly of  FIG.  8 E  according to an embodiment; 
         FIG.  9 A  shows an isometric view of a part of an insulating element having inner signal contacts according to an embodiment; 
         FIG.  9 B  shows an isometric cross-sectional view of the part of the insulating element having inner signal contacts according to an embodiment; 
         FIG.  9 C  shows a cross-sectional side view of the part of the insulating element having inner signal contacts according to an embodiment; 
         FIG.  10 A  shows an isometric view of a part of an insulating element according to an embodiment; 
         FIG.  10 B  shows a cross-sectional top view of the part of the insulating element having wires according to an embodiment; 
         FIG.  11 A  shows an isometric view of a part of a further embodiment of an insulating element having inner signal contacts according to an embodiment; 
         FIG.  11 B  shows an isometric view of a part of a further embodiment of an insulating element according to an embodiment; 
         FIG.  12 A  shows a cross-sectional view of a first embodiment of a first insulating part having inner signal contacts in a partly assembled state according to an embodiment; 
         FIG.  12 B  shows a cross-sectional view of the first embodiment of the first insulating part having inner signal contacts in a fully assembled state according to an embodiment; 
         FIG.  12 C  shows a cross-sectional view of a second embodiment of a second insulating part having the inner signal contacts in a final position, but not yet in a fully assembled state according to an embodiment; 
         FIG.  12 D  shows a cross-sectional view of the second embodiment of the first insulating part having the inner signal contacts in a fully assembled state according to an embodiment; 
         FIG.  13 A  shows an isometric view of a first embodiment of a first insulating part having two press-fit elements according to an embodiment; 
         FIG.  13 B  shows a cross-sectional top view of the first insulating part according to an embodiment; 
         FIG.  13 C  shows a cross-sectional view of one of the press-fit elements engaging a second insulating part according to an embodiment; 
         FIG.  14 A  shows an isometric view of a second embodiment of a first insulating part having two press-fit elements according to an embodiment; 
         FIG.  14 B  shows a cross-sectional top view of the first insulating part according to an embodiment; 
         FIG.  14 C  shows a cross-sectional view of one of the press-fit elements engaging a second insulating part according to an embodiment; 
         FIG.  15 A  shows an isometric view of a first insulating part having a locking element according to an embodiment; 
         FIG.  15 B  shows a cross-sectional top view of the first insulating part according to an embodiment; 
         FIG.  15 C  shows a cross-sectional view of the locking element engaging a second insulating part according to an embodiment; 
         FIG.  16 A  shows an isometric view of a first insulating part having a locking element according to an embodiment; 
         FIG.  16 B  shows a cross-sectional top view of the first insulating part according to an embodiment; 
         FIG.  16 C  shows a cross-sectional view of the locking element engaging a second insulating part according to an embodiment; 
         FIG.  17 A  shows an isometric view of a first insulating part having a pin and a second insulating part having a slot in a partly assembled state according to an embodiment; 
         FIG.  17 B  shows an isometric view of the first insulating part and the second insulating part in a fully assembled state according to an embodiment; 
         FIG.  18 A  shows an isometric view of a first insulating part having two tongues according to an embodiment; 
         FIG.  18 B  shows a cross-sectional view of the first insulating part and a second insulating part showing one of the tongues in a corresponding groove of the second insulating part according to an embodiment; 
         FIG.  18 C  shows an enlarged view of the tongue in the groove of  FIG.  18 B  according to an embodiment; 
         FIG.  18 D  shows a cross-sectional view of a first insulating part having a tongue and a second insulating part having a groove according to an embodiment; 
         FIG.  18 E  shows an enlargement of the tongue in the groove of  FIG.  18 D  according to an embodiment; 
         FIG.  19 A  shows an isometric view of a first insulating part and a second insulating part according to an embodiment; 
         FIG.  19 B  shows a cross-sectional view of the first insulating part and the second insulating part according to an embodiment; 
         FIG.  20 A  shows an isometric view of a first insulating part and a second insulating part according to an embodiment; 
         FIG.  20 B  shows an isometric cross-sectional view of the first insulating part and the second insulating part according to an embodiment; 
         FIG.  20 C  shows a cross-sectional side view of the first insulating part and the second insulating part according to an embodiment; 
         FIG.  21 A  shows a first step of mounting a first insulating part to inner signal contacts according to an embodiment; 
         FIG.  21 B  shows a second step of mounting the first insulating part to the inner signal contacts according to an embodiment; 
         FIG.  21 C  shows a step of mounting a second insulating part to the assembly of the first insulating part and the inner signal contacts according to an embodiment; 
         FIG.  22 A  shows a step of mounting a second insulating part to inner signal contacts according to an embodiment; 
         FIG.  22 B  shows a step of mounting a first insulating part to the assembly of the second insulating part and the inner signal contacts according to an embodiment; 
         FIG.  23 A  shows a step of inserting inner signal contacts into a first insulating part according to an embodiment; 
         FIG.  23 B  shows a step of attaching wires to the inner signal contacts according to an embodiment; and 
         FIG.  23 C  shows a step of attaching a second insulating part to the assembly of the first insulating part and the inner signal contacts according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
       FIG.  1    depicts an exploded view of a connector  10 , in particular a female connector, including two elongated inner signal contacts  12  arranged generally parallel to each other along an axial direction  14  of the connector  10 . The signal contacts  12  have a first connection portion  16  for connecting the connector  10  to a mating connector, in particular a male connector, and a second connection portion  18  for connecting the signal contacts  12  to respective conductors  21  of a cable  22 . The conductors  21  may be strands. Furthermore, the conductors  21  may be embedded in a wire insulation  20 . The second connection portion  18  may include a termination element  24  including, for example, two crimping wings (shown in  FIGS.  3 A and  3 B ) or may have a welding portion having a welding opening  26  (shown in  FIG.  3 C ). The welding opening  26  may be used to connect the signal contacts  12  to respective conductors  21  of the cable  22  via laser welding or ultrasonic welding. Alternatively, resistance welding can be used to connect the signal contacts  12  to respective conductors  21  of the cable  22 . 
     The inner signal contacts  12  are arranged in an insulating element  28  which may form a di-electric housing. In the embodiment shown in  FIG.  1   , the insulating element  28  includes two separate insulating parts, a first insulating part  28   a  and a second insulating part  28   b,  which together enclose the inner signal contacts  12 . The first insulating part  28   a  and the second insulating part  28   b  may be attached to each other, for example, by a click-on connection, i.e., by a snap fit engagement. It is to be understood that the first insulating part  28   a  and the second insulating part  28   b  may be attached to each other by other suitable connections, as will be described further below. Furthermore, it is to be understood that the insulating element  28  may also be a one-part insulating element  28 , for example, produced by injection molding, i.e., by overmolding the inner signal contacts  12 . In such an insulating element  28 , undesirable air pockets may be minimized. 
     The first insulating part  28   a  fulfills the task of locking the signal contacts  12  in the axial direction  14  so that the inner signal contacts  12  maintain their axial position when the connector  10  is connected to a mating connector. It is to be understood that, additionally or alternatively, the second insulating part  28   b  may fulfill the task of locking the signal contacts  12  in the axial direction  14 . 
     The connector  10  further includes a first shielding part  31  and a second shielding part  33  both formed as half shells which together form an outer shielding contact  35 . The outer shielding contact  35  surrounds the inner signal contacts  12  and the insulating element  28  to provide a shield against interfering signals. However, the outer shielding contact  35  can also be used as an electrical conductor to transport electric power. At a distal end  37  of the connector  10 , the connector  10  includes multiple shielding contacts  39 . At a proximal end  41  of the connector  10 , the first shielding part  31  forms a cover  43 . The second shielding part  33  forms a crimping portion  45  at the proximal end  41  of the connector  10  to mechanically and electrically connect the outer shielding contact  35  to the cable  22 . Furthermore, the connector  10  includes an inner crimp ferrule  47  which is placed around the cable  22 . 
     The inner signal contacts  12  and the insulating element  28  together form a connector assembly  110  according to an embodiment of the present disclosure, as shown in  FIG.  2 A .  FIG.  2 B  shows an exploded view of the connector assembly  110 . 
       FIGS.  3 A,  3 B and  3 C  depict an isometric view of the inner signal contacts  12  according to various embodiments. The inner signal contacts  12  generally extend parallel to one another. Each inner signal contact  12  has a first connection portion  16  for connecting the signal contact  12  to a mating signal contact and a second connection portion  18  for connecting the signal contact  12  to a respective conductor  21  of a cable  22  (see  FIG.  1   ). The first connection portion  16  has a tube-like main section  29  defining a first center axis  98  and a funnel-shaped end section  30 . The tube-like main section  29  may have a round, in particular a generally circular or oval, or a polygonal cross-section. The second connection portion  18  defines a second center axis  100  where a center axis of the cable  22  is placed. A distance A between the center axes  98  of the first connection portions  16  may be equal or larger than a distance B between the center axes  100  of the second connection portions  18 . Alternatively, a distance A between the center axes  98  of the first connection portions  16  may be smaller than a distance B between the center axes  100  of the second connection portions  18 . In other words, the inner signal contacts  12  may be formed so that a pitch translation may be generated. Each of the inner signal contacts  12  may be formed so that the first center axis  98  is spaced apart in parallel from the second center axis  100 . 
     In another embodiment, shown in  FIG.  3 C , the inner signal contacts  12  differ from the inner signal contacts  12  of  FIGS.  3 A and  3 B  in that hooks  103  are formed at side surfaces of the first connection portions  16 . The hooks  103  help to axially fix the inner signal contacts  12  in the insulating element  28 . 
     The second connection portions  18  of the inner signal contacts  12  may include welding openings  26  (see  FIG.  3 C ) that are arranged to allow, for example, a laser beam to weld a conductor  21  to the inner signal contacts  12 . Alternatively, termination elements  24  can be formed at the second connection portions  18  so that the inner signal contacts  12  can be attached onto the wires insulating  20  of the cable  22  ( FIGS.  3 A and  3 B ). 
     The inner signal contacts  12  may include signal contact portions  50 . In one embodiment, the signal contact portions  50  may have an oval cross-section, as shown in  FIG.  3 A . In another embodiment the signal contact portions  50  may have a U-shaped cross-section, as shown in  FIG.  3 B . In yet another embodiment, the signal contact portions  50  may have a circular cross-section, as shown in  FIG.  3 C . It is to be understood that the shape of the signal contact portions  50  is not limited to the shapes shown in  FIGS.  3 A to  3 C . Rather, the signal contact portions  50  may be of any suitable shape. The signal portions  50  may be configured to at least reduce or even prevent a rotation and/or an axial movement of the at least one elongated inner signal contact  12  relative to the insulating element  28 . The signal portions  50  may be defined as blocking elements that provide a forward stop and/or a backward stop for the at least one elongated inner signal contact  12  in the insulating element  28 . A precise rotational control and limitation of movement of the inner signal contact  12  as well as a precise rigid back and forward stop of the inner signal contact  12  may thus be achieved. The signal portions  50  may also be configured to receive a wire insulation  20 . 
       FIGS.  4 A and  4 B  show cross-sectional views of a connector assembly  110  in a partly assembled state (see  FIG.  4 A ) and in a fully assembled state (see  FIG.  4 B ). The connector assembly  110  includes at least one elongated inner signal contact  12 , in the present embodiment two inner signal contacts  12 . Each inner signal contact  12  includes a first connection portion  16  having a tube-like main section  29  and a funnel-shaped end section  30 . The tube-like main section  29  may have a round, in particular a generally circular or oval, or a polygonal cross-section. The funnel-shaped end section  30  expands from one end of the tube-like main section  29  such that a maximum outer cross-sectional dimension C of the funnel-shaped end section  30  is greater than a maximum outer cross-sectional dimension of the tube-like main section  29 . 
     The at least one elongated inner signal contact  12  is accommodated in an elongated cavity  32  of the insulating element  28 . A first part of the cavity  32  is designed to generally form fittingly receive the tube-like main section  29 , i.e., a cross-sectional dimension of the first part of the cavity  32  is generally equal to the outer cross-sectional dimension of the tube-like main section  29 , and a second part of the cavity  32  makes room for the funnel-shaped end section  30 . In other words, a cross-sectional dimension D of the first part of the cavity  32 , also referred to as a minimum cross-sectional dimension D of the cavity  32 , corresponds to the outer cross-sectional dimension of the tube-like main section  29 , whereas a cross-sectional dimension of the second part of the cavity  32 , also referred to as a maximum cross-sectional dimension of the cavity  32 , is at least equal to or greater than the maximum outer cross-sectional dimension C of the funnel-shaped end section  30 . Since the maximum outer cross-sectional dimension C of the funnel-shaped end section  30  is greater than the maximum outer cross-sectional dimension of the tube-like main section  29 , the maximum outer cross-sectional dimension C of the flaring funnel-shaped end section  30  is also greater than the cross-sectional dimension D of the first part of the cavity  32 , i.e., the minimum cross-sectional dimension D of the cavity  32 . It is to be understood that the dimensions described herein may be diameters if the tube-like main section  29  and the cavity  32  are of circular cross-section. 
       FIGS.  5 A and  5 B  show an isometric view and a cross-sectional view, respectively, of the funnel-shaped end section  30  of the inner contact  12 . The funnel-shaped end section  30  includes a first end section part  36  and a second end section part  38 . The first end section part  36  and the second end section part  38  are separated by two air gaps  34 , i.e., there is a clearance between the first end section part  36  and the second end section part  38 . The first end section part  36  and the second end section part  38  may be diagonally arranged, i.e., arranged opposite from each other. Accordingly, the two air gaps  34  may be diagonally arranged, i.e., arranged opposite from each other. 
     As shown in  FIGS.  6 A to  6 C , each cavity  32  ends in a front opening  40  of the insulation element  28 , which allows a mating contact to be connected to the inner contact  12  arranged in the cavity  32 . Each front opening  40  is configured to receive the funnel-shaped end section  30  of the inner signal contact  12 . Two, for example, diagonally arranged chamfers  42  protrude into the front opening  40  and, more specifically, into the air gaps  34  of the funnel-shaped end section  30  received in the front opening  40 . 
     When the funnel-shaped end section  30  is received in the front opening  40 , the first end section part  36 , the second end section part  38  and the two chamfers  42  together define an inlet  44  configured to correctly guide a matching male signal contact (not shown) into the female inner signal contact  12 . The inlet  44  may form a 360-degree lead-in cone, in particular having an at least substantially closed perimeter, to guide the male signal contact into the inner signal contact  12 . Depending on the geometrical definition of the end section parts  36 ,  38  and the corresponding chamfers  42 , the inlet may be of round, in particular circular or oval, or of polygonal cross-section. 
       FIGS.  7 A and  7 B  show a part of the insulating element  28  having inner signal contacts  12  in a partly assembled state of the connector assembly  110 . The insulating element  28  includes at least one rib  46  in each cavity  32 . The rib  46  may be an extension of one of the chamfers  42  in a direction of the first center axis  98  defined by the respective inner signal contact  12 . The rib  46  engages one of the air gaps  34  when the funnel-shaped end section  30  of the inner signal contact  12  is inserted into the front opening  40  and thereby widens the funnel-shaped end section  30 . In a not fully assembled state ( FIGS.  7 A and  7 B ), the funnel-shaped end section  30  of the inner signal contact  12  is not in contact with the rib  46  and, thus, is in a relaxed state. 
       FIG.  7 C  shows an isometric view and  FIG.  7 D  shows a cross-sectional view of the part of the insulating element  28  having inner signal contacts  12  in a fully assembled state of the connector assembly  110 . When the inner signal contacts  12  are inserted into the insulating element  28 , the funnel-shaped end section  30 , in particular the first end section part  36  and the second end section part  38  are pushed apart by the rib  46  as shown in  FIGS.  7 C and  7 D . 
       FIGS.  8 A to  8 F  show cross-sectional top views and a cross-sectional side views of further embodiments of the connector assembly  110  in which the insulating element  28  includes at least one protrusion  52  and at least one recess  54  for each inner signal contact  12 . The at least one respective inner signal contact  12  also includes at least one protrusion  56  and at least one recess  58 , respectively. The at least one protrusion  52  of the insulating element  28  engages with the at least one recess  58  of the inner signal contact  12 , and vice versa. In other words, the protrusions  52 ,  56  and the recesses  54 ,  58  are configured to cooperate in order to substantially prevent a rotation and/or an axial movement of the inner signal contact  12  relative to the insulating element  28 . More specifically, the rotation and/or the axial movement of the inner signal contact  12  relative to the insulating element  28  is reduced, or minimized, or limited to some degree, such that only an insignificant amount of rotation and axial movement of the inner signal contact  12  relative to the insulating element  28  may occur. 
     The insulating element  28  may include two protrusions  52  for each inner signal contact  12 . One protrusion  52  of the insulating element  28  is arranged in front of the protrusion  56  of the inner signal contact  12  and one protrusion  52  of the insulating element  28  is arranged behind the protrusion  56  of the inner signal contact  12 , as shown in  FIGS.  8 A to  8 C . The protrusion  52  of the insulating element  28  arranged in front of the protrusion  56  of the inner signal contact  12  may function as a forward stop or a backward stop and the protrusion  52  of the insulating element  28  arranged behind the protrusion  56  of the inner signal contact  12  may function as a backward stop. A forward stop may reduce or even prevent an axial movement of the at least one elongated inner signal contact  12  relative to the insulating element  28  in a forward direction, i.e., in a direction towards the funnel-shaped end section  30  of the inner signal contact  12 . A backward stop may reduce or even prevent an axial movement of the at least one elongated inner signal contact  12  relative to the insulating element  28  in a backward direction, i.e., in a direction towards the second connection portion  18  of the inner signal contact  12 . 
       FIG.  9 A  shows an isometric view of a part of an insulating element  28  having two inner signal contacts  12 . Each inner signal contact  12  includes a hole  62  defined to receive a corresponding control element  60  of the insulating element  28 . The control elements  60  are arranged such that they engage with the holes  62  when the connector assembly  110  is correctly assembled, i.e., when the inner signal contacts  12  are correctly embedded in the insulating element  28 .  FIGS.  9 B  and  FIG.  9 C  show the control elements  60  inserted into the holes  62  of U-shaped signal contact portions  50  of the inner signal contacts  12 . It is to be understood that the holes  62  and, thus, the control elements  60  may also be arranged at other parts of the inner signal contacts  12 . The control elements  60  are visible in the holes  62  of the inner signal contacts  12  when the inner signal contacts  12  reach an end-position during the assembling of the connector assembly  110 . Thus, a visual control of the end-position of the inner signal contacts  12  is possible when the inner signal contacts  12  are mounted in the insulating element  28 . 
       FIGS.  10 A and  10 B  show an insulating element  28  according to a further embodiment. The insulation element  28  includes at least one clamping element  48  in each cavity  32 , which is configured to secure the wire insulation  20  of a cable  22  (not shown) and/or a conductor  21  to which the respective inner signal contact  12  is connected. To secure the wire insulation  20  or the conductor  21  in the insulating element  28 , a gap defined by two opposing clamping elements  48  is less than a main diameter of the wire insulation  20  or the conductor  21 . Thus, the wire insulation  20  or the conductor  21  is clamped in the insulating element  28  when the wire insulation  20  or the conductor  21  is inserted into the gap. 
       FIG.  11 A  shows an isometric view of a part of the insulating element  28  having two inner signal contacts  12  according to a further embodiment. The inner signal contacts  12  each include a termination element  24 , for example, a pair of crimping wings, arranged at the second connection portion  18 . The termination element  24  may be configured to secure a wire insulation  20  or a conductor  21 , e.g., a conductor, in the inner signal contact  12 . The insulating element  28  includes at least one retaining element  64  for each inner signal contact  12 , which is configured to secure at least one of the respective termination element  24 , the respective wire insulation  20 , the conductor  21  and a respective signal contact portion  50  in the insulating element  28 . Each retaining element  64  may be designed as a snap arm. Two opposing retaining elements  64  may form a cavity that is configured to hold or secure the termination element  24  or the wire insulation  20 . 
       FIG.  11 B  shows another embodiment of a part of an insulating element  28  in which the retaining element  64  is designed as a bracket that encloses at least one of the termination element  24 , the wire insulation  20 , the conductor  21  and the signal contact  50 . The shape of the bracket may be adapted to the contour of the received element. For example, the bracket may define circular cavities to receive the signal contact portions  50  of the inner signal contacts  12 . 
       FIG.  12 A  shows a cross-sectional view of a further embodiment of a first insulating part  28   a  having two inner signal contacts  12  in a partly assembled state. The first insulating part  28   a  may be radially mounted to the inner signal contacts  12 . As shown in  FIG.  12 B , the inner signal contacts  12 , in particular the signal contact portions  50 , are pinched into the first insulating part  28   a  in a fully assembled state of the connector assembly  110 . To this end, the signal contact portions  50  may have a greater cross-sectional dimension than respective cavities  66  of the first insulating part  28   a  (see  FIG.  12 A ). By pressing the signal contact portions  50  into the cavities  66 , the cross-sectional dimension of the signal contact portions  50  is reduced to a cross-sectional dimension of the cavity  66  as shown in  FIG.  12 B . Furthermore, due to the reduction of the cross-sectional dimension of the signal contact portions  50 , the wire insulations  20  or the conductors  21  attached to the inner signal contacts  12  are secured in the signal contact portions  50 . The second insulating part  28   b  of the insulating element  28  may then be axially slid onto the inner signal contacts  12  in a direction of the first center axis  98  defined by the inner signal contacts  12  such that the inner signal contacts  12  are fully enclosed by the first insulating part  28   a  and the second insulating part  28   b.  A detailed description of an assembly process will be described further below. 
     Alternatively, according to another embodiment, the inner signal contacts  12  may be inserted into the second insulating part  28   b  as shown in  FIG.  12 C . More specifically,  FIG.  12 C  shows the inner signal contacts  12  in their final position in the second insulation part  28   b,  but not yet in their fully assembled state since the first insulating part  28   a  is still to be mounted. Thus, one elongated inner signal contact  12  is pinched into the first insulating part  28   a  by radially mounting the first insulating part  28   a  in respect of the at least one elongated inner signal contact  12  and the second insulating part  28   b,  as shown in  FIG.  12 D . The cross-sectional dimension of the signal contact  50  is reduced to a cross-sectional dimension of the cavity  66  by pressing the first insulating part  28   a  onto the signal contact  50 . Thus, the inner signal contact  12 , in particular the signal contact  50 , is pinched into the first insulating part  28   a  as shown in  FIG.  12    D in a fully assembled state of the connector assembly  110 . 
       FIGS.  13 A to  13 C and  14 A to  14 C  show two embodiments of a first insulating part  28   a  having two press fit elements  68 . The press fit elements  68  may be formed as cuboidal elements having protrusions  74  that protrude over the surfaces of the cuboidal elements, as shown in  FIGS.  13 A and  14 A . Respective elements of the second insulating part  28   b  may be formed as cuboidal recesses  76  configured to receive the press fit elements  68  of the first insulating part  28   a.  A cross-sectional dimension of the cuboidal recesses  76  may be substantially the same as a cross-sectional dimension of the corresponding press fit elements  68  (the protrusions  74  not considered). When the first insulating part  28   a  and the second insulating part  28   b  are radially mounted to the inner signal contacts  12 , the press fit elements  68  are inserted into the corresponding cuboidal recesses  76 . The press fit elements  68  are secured in the recesses  76  by means of the protrusions  74 . More specifically, the press fit elements  68  have to be pressed into the recesses  76  since the protrusions  74  lead to a cross-sectional dimension of the press fit elements  68  greater than that of the recesses  76 . Depending on the arrangement of the protrusions  74 , either radial forces  70  (see  FIG.  13 C ) or axial forces  72  (see  FIG.  14 C ) act between the first insulating part  28   a,  in particular the press fit elements  68 , and the second insulating part  28   b.    
     According to other embodiments shown in  FIGS.  15 A to  15 C and  16 A to  16 C , a first insulating part  28   a  has at least one locking element  78 . The locking element  78  may be formed as a cuboidal element having a mushroom head  79  ( FIGS.  15 A,  15 C ) or having a Y-shaped or forked head  81  ( FIGS.  16 A,  16 C ). The second insulating part  28   b  includes a matching substantially cuboidal locking recess  80  configured to receive the locking element  78  of the first insulating part  28   a.  The locking recess  80  may include a first recess part  80   a  and a second recess part  80   b,  as shown in  FIGS.  15 C and  16 C . A cross-sectional dimension of the first recess part  80   a  may be substantially the same as a cross-sectional dimension of the cuboidal locking element  78 , i.e., the cuboidal locking element  78  fits into the first recess part  80   a.  A maximum outer cross-sectional dimension of the mushroom head  79  or the fork head  81  is greater than the cross-sectional dimension of the first recess part  80   a.  Thus, the locking element  78  has to be pressed through the first recess part  80   a  of the locking recess  80  until the mushroom head  79  or the fork head  81  reaches into the second recess part  80   b.  A cross-sectional dimension of the second recess part  80   b  of the locking recess  80  is greater than the maximum outer cross-sectional dimension of the mushroom head  79  or the forked head  81  and, thus, also greater than the first recess part  80   a  such that the first recess part  80   a  and the second recess part  80   b  of the locking recess  80  define a shoulder  82  at their transition ( FIGS.  15 C and  16 C ). When the locking element  78  is fully inserted into the locking recess  80 , the mushroom head  79  or the forked head  81  sits on the shoulder  82  and thereby secures the first insulating part  28   a  to the second insulating part  28   b  ( FIGS.  15 C and  16 C ). 
       FIG.  17 A  shows an embodiment of a first insulating part  28   a  and a second insulating part  28   b  having a locking pin  84  and a locking slot  86 , respectively, in a partly assembled state of the connector assembly  110 . The locking slot  86  is configured to receive the locking pin  84 . The locking slot  86  includes a first slot part  86   a  and a second slot part  86   b.  A cross-sectional dimension of the first slot part  86   a  of the locking slot  86  may be substantially the same as a cross-sectional dimension of the locking pin  84 , i.e., the locking pin  84  fits into the first slot part  86   a  of the locking slot  86  (see  FIG.  17 A ). A cross-sectional dimension of the second slot part  86   b  is greater than the cross-sectional dimension of the locking pin  84  such that the first slot part  86   a  and the second slot part  86   b  define a shoulder  90  (see  FIG.  17 B ). The locking slot  86  may be similar to the locking recess  80  described above. When the locking pin  84  is fully inserted into the locking slot  86  the locking pin  84  may be deformed by means of a punch tool  88 . The punch tool  88  presses on to a free end of the locking pin  84  such as to deform the free end of the locking pin  84  into a mushroom head that sits on the shoulder  90 , thereby securing the first insulating part  28   a  to the second insulating part  28   b  (see  FIG.  17 B ). The locking pin  84  may be deformable in a cold or a hot state, i.e., the locking pin  84  is deformable by means of the punch tool  88  with or without preheating the locking pin  84  or the punch tool  88 . 
       FIG.  18 A  shows a first insulating part  28   a  having two tongues  96 . The second insulating part  28   b  includes corresponding grooves  94  in which the tongues  96  can be received. The first insulating part  28   a  is secured to the second insulating part  28   b  by inserting the tongues  96  into their associated grooves  94  and axially sliding the first insulating part  28   a  relative to the second insulating part  28   b  in a direction of the center axes  98  defined by the inner signal contacts  12 .  FIGS.  18 B and  18 C  show a cross-sectional view of one of the tongues  96  inserted into its associated groove  94 . A maximum outer dimension of the tongue  96  may be substantially the same as a maximum inner dimension of the groove  94 , i.e., the tongue  96  may fit into the groove  94 . In an alternative embodiment shown in  FIGS.  18 D and  18 E , the maximum outer dimension of the tongue  96  may be somewhat greater than the maximum inner dimension of the groove  94 . Therefore, the tongue  96  has to be forced into the groove  94  and is somewhat deformed when fully inserted into the groove  94 . 
       FIGS.  19 A,  19 B and  20 A- 20 C  show two embodiments of an insulating element  28  in which a first insulating part  28   a  includes a locking cavity  104  and a second insulating part  28   b  includes a locking protrusion  106  to be received in the locking cavity  104 . The locking protrusion  106  extends into the locking cavity  104  when the connector assembly  110  is correctly assembled. 
       FIGS.  21 A and  21 B  depict a process of assembling a connector assembly  110  having an insulating element  28  as described in connection with  FIGS.  14 A to  14 C . First, conductors  21  of a cable  22  are connected to the inner signal contacts  12  by attaching the wire insulations  20  to the inner signal contacts  12  by means of a termination element  24 , for example, crimping wings. A first insulating part  28   a  is then radially mounted to the inner signal contacts  12  such that the inner signal contacts  12  are embedded in cavities  32  of the first insulating part  28   a.  Once the inner signal contacts  12  are arranged in the cavities  32 , the first insulation part  28   a  is axially slid into position along the inner signal contacts  12  in a direction of the center axes  98  defined by the inner signal contacts  12  (see  FIG.  21 B ). By sliding the first insulating part  28   a  in the direction of the center axes  98 , funnel-shaped end sections  30  of the inner signal contacts  12  are optionally widened by means of ribs  46 , if ribs  46  are arranged in a front opening  40  of the first insulation part  28   a,  as described above. Subsequently, a second insulating part  28   b  is radially mounted to the inner signal contacts  12  and secured to the first insulating part  28   a  (see  FIG.  21 C ) as described above. 
       FIGS.  22 A and  22 B  depict an alternative process of assembling a connector assembly  110  as described herein. First, conductors  21  of a cable  22  are connected to the inner signal contacts  12  by attaching the wire insulations  20  to the inner signal contacts  12  by means of a termination element  24 , for example crimping wings. A second insulating part  28   b  is then radially mounted to the inner signal contacts  12  such that the inner signal contacts  12  are embedded in cavities  32  of the second insulating part  28   b  ( FIGS.  22 A ). Once the inner signal contacts  12  are secured in the second insulating part  28   b  as described above, a first insulating part  28   a  is mounted to the second insulating part  28   b,  as shown in  FIG.  22 B . The first insulation part  28   a  is axially slid onto the inner signal contacts  12  in a direction of the center axes  98  defined by the inner signal contacts  12 . By sliding the first insulating part  28   a  in the direction of the center axes  98  of the inner signal contacts  12 , funnel-shaped end sections  30  of the inner signal contacts  12  enter front openings  40  of the first insulating part  28   a  and are optionally widened by means of ribs  46 , if ribs  46  are arranged in the front openings  40 , as described above. The first insulating part  28   a  is secured to the second insulation part  28   b  by means as described above, for example, by means of tongues  96  and grooves  94 . 
       FIGS.  23 A to  23 C  depict another process of assembling a connector assembly  110 , in particular for inner signal contacts  12  having welding openings  26  to connect the inner signal contacts  12  to conductors  21  of a cable  22  via welding, e.g., laser, ultrasonic or resistance welding.  FIG.  23 A  shows a step of inserting inner signal contacts  12  into a first insulating part  28   a.  The inner signal contacts  12  are axially slid into cavities  32  of the first insulating part  28   a  in a direction of the center axes  98  defined by the inner signal contacts  12 . Thus, the inner signal contacts  12  may be secured in the first insulating part  28   a  by features as described above, for example, by means of hooks  103 . Once the inner signal contacts  12  are secured in the first insulating part  28   b,  a step of attaching conductors  21  of a cable  22  to the inner contacts  12  follows, as shown in  FIG.  23 B . The conductors  21  are connected to the inner signal contacts  12  via laser welding or ultrasonic welding or resistance welding in the welding openings  26 . Subsequently, a second insulating part  28   b  is attached to the first insulating part  28   a  (see  FIG.  23 C ). More specifically, the second insulating part  28   b  is radially mounted to the inner signal contacts  12  and the first insulating part  28   a.  Therein, the second insulation part  28   b  is secured to the first insulating part  28   a  by means as described above. 
     While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments and are by no means limiting and are merely prototypical embodiments. 
     Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled. 
     As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above. 
     It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact. 
     The terminology used in the description of the various described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context. 
     Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any order of arrangement, order of operations, direction or orientation unless stated otherwise.