Patent Publication Number: US-11641085-B2

Title: Electrical connector assembly and method for manufacturing same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of priority to U.S. Provisional Patent Application No. 63/091,373 filed on Oct. 14, 2020, the entire disclosure of which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     Right angled electrical connectors used to terminate wire electrical cables have terminals with a connection end that is designed to interconnect with a corresponding mating terminal and an attachment end attached to the wire cable that is arranged at a right angle to the connection end. In some applications, it is desirable to have the wire cable in a particular orientation relative to a connector housing holding the terminal. In prior connector designs, the terminal and housing were designed so that the cable was in one fixed orientation, e.g. 6 o&#39;clock position, or in one of four orientations, e.g. 12 o&#39;clock, 3 o&#39;clock, 6 o&#39;clock, or 9 o&#39;clock. Changing these fixed orientations requires an investment of time and money to develop new connector tooling to manufacture a connector with a different cable orientation. 
     SUMMARY 
     According to one or more aspects of the present disclosure, an electrical connector assembly includes an electrical terminal having a connection portion configured to interface with a corresponding mating electrical connector and an attachment portion configured to interface with an electrical cable. The connection portion is angled relative to the attachment portion. The electrical connector assembly also includes a cylindrical inner housing sleeve formed of a polymeric material in which the connection portion of the electrical terminal is disposed and an outer connector housing formed of a polymeric material having a smooth bore configured to receive the inner housing sleeve containing the electrical terminal. The bore and inner housing sleeve are sized such that the inner housing sleeve is in an interference fit condition when received within the bore. The electrical connector assembly is assembled by a process including the step of inserting the inner housing sleeve within the bore of the outer connector housing and affixing the inner housing sleeve to the outer connector housing by welding the inner housing sleeve to the outer connector housing. 
     In one or more embodiments of the electrical connector assembly according to the previous paragraph, the welding may be performed by selectively melting a portion of the polymeric material of the inner housing sleeve and a portion of the polymeric material of the outer connector housing. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the welding may be performed by using a sonic welding process. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, a curved first rib may extend radially from the inner housing sleeve. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the first rib may be sized such that the inner housing sleeve is in an interference fit condition with the bore when the inner housing sleeve is received within the bore and wherein the first rib is welded to the outer connector housing. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, a curved second rib may extend radially from the inner housing sleeve and the second rib may be sized such that the second rib is in a interference fit condition when the inner housing sleeve is received within the bore. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the inner housing sleeve and the bore may be configured to allow the attachment portion to be arranged at any radial orientation relative to a longitudinal axis of the bore. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the connection portion may be angled perpendicularly relative to the attachment portion. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the outer connector housing and the inner housing sleeve are formed of the same, i.e., an identical, polymeric material. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the polymeric material forming the outer connector housing and the inner housing sleeve is 20% glass filled polybutylene terephthalate. 
     According to one or more aspects of the present disclosure, a method of assembling an electrical connector assembly is presented. The having an electrical terminal electrical connector assembly has a connection portion configured to interface with a corresponding mating electrical connector and an attachment portion configured to interface with an electrical cable, a cylindrical inner housing sleeve formed of a polymeric material in which the connection portion of the electrical terminal is disposed and an outer connector housing formed of a polymeric material having a smooth bore configured to receive the inner housing sleeve containing the electrical terminal. The connection portion is angled relative to the attachment portion. The bore and inner housing sleeve are sized such that the inner housing sleeve is in an interference fit condition when received within the bore. The method includes the steps of inserting the inner housing sleeve within the bore of the outer connector housing and affixing the inner housing sleeve to the outer connector housing by welding a portion of the inner housing sleeve to a portion of the outer connector housing. 
     In one or more embodiments of the method according to the previous paragraph, the method may further include the step of selectively melting a portion of the polymeric material of the inner housing sleeve and a portion of the polymeric material of the outer connector housing. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the welding is performed by using a sonic welding process. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, a curved first rib may extend radially from the inner housing sleeve. The first rib may be sized such that the inner housing sleeve is in an interference fit condition with the bore when the inner housing sleeve is received within the bore. The method may further include the step of welding the first rib to the outer connector housing. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the inner housing sleeve may define a curved second rib radially extending from the inner housing sleeve. The second rib may be sized such that the second rib is in an interference fit condition when the inner housing sleeve is received within the bore. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the inner housing sleeve and the bore may be configured to allow the attachment portion to be arranged at any radial orientation relative to a longitudinal axis of the bore prior to the affixing step. 
     In one or more embodiments of the electrical connector assembly according to any one of the previous paragraphs, the connection portion may be angled perpendicularly relative to the attachment portion. 
     According to one or more aspects of the present disclosure, a coaxial connector assembly includes a coaxial terminal having a connection portion extending along a first axis and configured to interface with a corresponding mating coaxial connector and an attachment portion extending along a second axis and attached to a coaxial electrical cable. The first axis is arranged at a ninety-degree angle relative to the second axis. The coaxial connector assembly further includes a cylindrical inner housing sleeve formed of a polymeric material in which the connection portion of the coaxial terminal is disposed and an outer connector housing formed of a polymeric material having a bore extending along the first axis through the outer connector housing. A first side of the outer connector housing extends parallel to the first axis and a second side extending parallel to the first axis and is arranged generally perpendicular to the first side. The inner housing sleeve is fixed within the outer connector housing such that the second axis of the attachment portion is nonparallel to the first side of the outer connector housing and nonparallel to the second side of the outer connector housing. 
     In one or more embodiments of the coaxial connector assembly according to the previous paragraph, an inner surface of the bore may be smooth. The inner housing sleeve may be welded to the outer connector housing. 
     In one or more embodiments of the coaxial connector assembly according to any one of the previous paragraphs, the first rib may be sized such that the inner housing sleeve is in an interference fit condition with the bore when the inner housing sleeve is received within the bore and wherein the first rib is sonically welded to the outer connector housing. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a perspective view of an electrical connector according to some embodiments; 
         FIG.  2    is an exploded perspective view of the electrical connector of  FIG.  1    according to some embodiments; 
         FIG.  3 A  is a rear perspective view of an outer connector housing of the electrical connector of  FIG.  1    according to some embodiments; 
         FIG.  3 B  is a front perspective view of an inner housing sleeve of the electrical connector of  FIG.  1    according to some embodiments; 
         FIG.  4 A  is cross-section side view of the electrical connector of  FIG.  1    prior to the insertion of the inner housing sleeve of  FIG.  3 B  into the outer connector housing of  FIG.  3 A  according to some embodiments; 
         FIG.  4 B  is cross-section side view of the electrical connector of  FIG.  1    after insertion of the inner housing sleeve of  FIG.  3 B  into the outer connector housing of  FIG.  3 A  according to some embodiments; 
         FIG.  5    is rear view of the electrical connector of  FIG.  1    showing various possible “clock positions” of a terminal according to some embodiments; and 
         FIG.  6    is a flow chart of a process or method of forming the electrical connector assembly of  FIG.  1     
     
    
    
     DETAILED DESCRIPTION 
     This application is directed to an electrical connector The connector is designed so that a right-angled terminal and a wire cable attached to it can be arranged at any angle relative to an outer connector housing of the connector. This is accomplished with a smooth bore cavity in the outer housing that receives an inner housing sleeve holding the right-angled terminal. The inner housing sleeve is in an interference fit with the outer connector housing once it is inside the bore. After the inner housing sleeve is arranged in the bore to have the desired “clock position” of the right angled terminal relative to the outer connector housing, the inner housing sleeve is sonically welded to an inner wall of the bore though the outer connector housing to fix the “clock position” of the right angled terminal. 
       FIGS.  1  and  2    illustrate a non-limiting example of a right angled coaxial electrical connector assembly, hereinafter referred to as the assembly  100  conforming to the FAKRA standard. FAKRA is an abbreviation for the German term Fachnormenausschuss Kraftfahrzeugindustrie used by the Automotive Standards Committee in the German Institute for Standardization [Deutsches Institut für Normung (DIN)], representing international standardization interests in the automotive field. The FAKRA standard provides a system, based on keying and color coding, for proper connector attachment of coaxial electrical connectors. Like socket keys can only be connected to like plug keyways in FAKRA connectors. Secure positioning and locking of connector housings is facilitated by way of a FAKRA defined catch on the socket housing and a cooperating latch on the plug housing. The FAKRA standard is incorporated in United States Council for Automotive Research (USCAR) USCAR-18 standard. 
     The assembly  100  includes an electrical terminal  102  having a connection portion  104  extending along a first axis X that is configured to interface with a corresponding mating electrical connector (now shown) and an attachment portion  106  configured to interface with a coaxial electrical cable (not shown). In the illustrated example, the electrical terminal  102  is an outer shield terminal connected to the outer shield of the coaxial cable. The connection portion  104  extends along a second axis Y that is noncoaxial with the first axis X such that the connection portion  104  is angled relative to the attachment portion  106 . In the illustrated embodiment, the attachment portion  106  is arranged generally perpendicular or at a right angle to the connection portion  104  of the electrical terminal  102 . Alternative embodiments may be envisioned in which the attachment portion  106  and the cable is arranged at an angle between 0 and 90 degrees to the connection portion  104  of the electrical terminal  102 . 
     The connection portion  104  of the electrical terminal  102  is secured within a cylindrical inner housing sleeve  110 . The inner housing sleeve  110  is formed of an insulative polymeric material, such as 20% glass filled polybutylene terephthalate. 
     The assembly  100  also includes an outer connector housing  112  having a smooth bore  114 , shown in  FIG.  3 A , extending from an attachment aperture  116  in a rear surface  118  of the outer connector housing  112  to a connection aperture  120  in a front surface  122  of the outer connector housing  112 . The smooth bore  114  is configured to receive the inner housing sleeve  110  containing the electrical terminal  102  though the attachment aperture  116 . The rear surface  118  of the outer connector housing  112  is generally flat. The outer connector housing  112  is also formed of an insulative polymeric material, such as the same 20% glass filled polybutylene terephthalate material forming the inner housing sleeve  110 . The smooth bore  114  and inner housing sleeve  110  are sized such that the inner housing sleeve  110  is in an interference fit condition when received within the smooth bore  114 . 
     The inner housing sleeve  110  has concentric curved first and second ribs  124 ,  126 , shown in  FIGS.  3 B and  4 A , that extend radially from the inner housing sleeve  110 . These first and second ribs  124 ,  126  are in an interference fit condition with the inner wall  128  of the smooth bore  114  when the inner housing sleeve  110  is inserted within the smooth bore  114 , as shown in  FIG.  4 B . 
     The smooth bore  114  and the flat rear surface  118  of the outer connector housing  112  cooperate with the curved first and second ribs  124 ,  126  of the inner housing sleeve  110  to allow the attachment portion  106  of the electrical terminal  102  to be arranged at any radial angle or “clock position” relative the outer connector housing  112  as shown in  FIG.  5   . 
     Once the attachment portion  106  is arranged in the desired clock position, the inner housing sleeve  110  is affixed to the outer connector housing  112  by welding the inner housing sleeve  110  to the inner wall  128  of the smooth bore  114 , thereby permanently arranging the attachment portion  106  of the electrical terminal  102  in the desired clock position. The rearmost first rib  124  defines a raised ridge  130  that extends across the first rib  124 , as best shown in  FIGS.  4 A and  4 B . It is this ridge  130  that primarily forms the weld between the inner housing sleeve  110  and the outer connector housing  112 . 
     A method  200  of assembling the assembly  100  is shown in the diagram of  FIG.  6   . The various steps of the method  200  are outlined below: 
     STEP  202 , INSERT THE INNER HOUSING SLEEVE WITHIN THE BORE OF THE OUTER CONNECTOR HOUSING, includes inserting the inner housing sleeve  110  within the smooth bore  114  of the outer connector housing  112 ; 
     STEP  204 , AFFIX THE INNER HOUSING SLEEVE TO THE OUTER CONNECTOR HOUSING BY WELDING A PORTION OF THE INNER HOUSING SLEEVE TO A PORTION OF THE OUTER CONNECTOR HOUSING, includes affixing the inner housing sleeve  110  to the outer connector housing  112  by welding a portion of the inner housing sleeve  110  to a portion of the outer connector housing  112 ; 
     STEP  206 , SELECTIVELY MELT OF A PORTION OF THE POLYMERIC MATERIAL OF THE INNER HOUSING SLEEVE AND A PORTION OF THE POLYMERIC MATERIAL OF THE OUTER CONNECTOR HOUSING, includes selectively melting a portion of the polymeric material of the inner housing sleeve  110  and a portion of the polymeric material of the outer connector housing  112 , for example by using a sonic welding process; and 
     STEP  208 , WELD THE FIRST RIB TO THE OUTER CONNECTOR HOUSING, includes welding the first rib  124  to the outer connector housing  112 . 
     While the exemplary embodiment is a coaxial electrical connector assembly, other connector assembly embodiments may be envisioned that are adapted for use with single conductor stranded or solid wire cables, fiber optic cables, pneumatic tubes, hydraulic tubes, or a hybrid connector assembly including two or more of the items listed above. 
     While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention is not limited to the disclosed embodiment(s), but that the invention will include all embodiments falling within the scope of the appended claims.