Patent Publication Number: US-6984150-B2

Title: Cable connector

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention generally relates to cable connectors such as balanced transmission cable connectors, and more particularly, to a cable connector such as a balanced transmission cable connector which is suitable for transmitting high speed signals. 
   2. Description of the Related Art 
   There are two data transmission methods. One is a normal transmission method and the other is a balanced transmission method. In the normal transmission method, one electric wire is used for every datum. To the contrary, in the balanced transmission method, a pair of electric wires is used for every datum. A “+” signal and a “−” signal are simultaneously transmitted in the balanced transmission method. The magnitude of the “−” signal is equal to that of the “+” signal. The direction of the “−” signal is reverse to that of the “+” signal. Use of the balanced transmission method is on the increase for data transmission because the balanced transmission method has an advantage in that it is more robust against noise than the normal transmission method. A balanced transmission cable connector has a structure where a plug is provided at an end of a balanced transmission cable and the plug is covered with a shield cover. The balanced transmission cable connector is applied to the balanced transmission method and used for connecting a computer and a server. 
     FIG. 1  is an exploded perspective view of a related art balanced transmission cable connector  10 .  FIG. 2  is a cross-sectional view of the balanced transmission cable connector  10  shown in  FIG. 1 . In  FIG. 1  and  FIG. 2 , a direction of X 1 –X 2  shows a width direction of the balanced transmission cable connector  10 . A direction of Y 1 –Y 2  shows a longitudinal direction of the balanced transmission cable connector  10 . A direction of Z 1 –Z 2  shows a height direction of the balanced transmission cable connector  10 . A direction of Y 1  shows a rear direction and a direction of Y 2  shows a front direction.  FIG. 3  is a cross-sectional view of a related art balanced transmission cable  20 . The balanced transmission cable connector  10  is connected to an end part of the balanced transmission cable  20  having a structure shown in FIG.  3 -(A) and FIG.  3 -(B). 
   As shown in FIG.  3 -(A), the balanced transmission cable  20  has a structure where a lot of pair electric wires  21  are arranged inside of a tube which has a double covering structure formed by a tube-shaped electrically insulating outer covering part  27  and a shielding mesh  28 . As shown in FIG.  3 -(B), each of the pair electric wires  21  has a structure where a pair of first and second covered signal electric wires  22 - 1  and  22 - 2  and a drain wire  26  are wound in a spiral form by a metal tape  25  so as to be bound. The first and second covered signal electric wires  22 - 1  and  22 - 2  and the drain wire  26  are extended from an end part of the pair electric wire  21  to the outside. Head end parts of the first and second covered signal electric wires  22 - 1  and  22 - 2  are processed so that first and second signal wires  23 - 1  and  23 - 2 , respectively, are exposed in a naked state. The first and second covered signal electric wires  22 - 1  and  22 - 2  include electrically insulating covering parts  24 - 1  and  24 - 2 , respectively. The first and second covered signal electric wires  22 - 1  and  22 - 2  form a pair wire. In addition, as shown in  FIG. 2 , an end part of the balanced transmission cable  20  is clamped by a clamp member  27 . 
   Referring back to  FIG. 1  and  FIG. 2 , a relay board  12  is fixed to a Y 1  side of a plug assembly  11 . The pair electric wires  21  provided at the end part of the balanced transmission cable  20  are arranged in X directions by an electric wire arranging member  15 . The first and second covering signal electric wires  23 - 1  and  23 - 2  and the drain wire  26 , which are further extended from the ends of the pair electric wires  21 , are solder-connected to a terminal part situated at the Y 1  side of the relay board  12 , as shown by a numerical reference  14 . Shield covers  31  and  32  cover the plug assembly  11 , the relay board  12  and the electric wire arranging member  15 . The shield covers  31  and  32  are engaged with the clamp member  27 . The plug assembly  11  and the clamp member  27  limit movement in the Y 1  direction. A synthetic resin part  16  is a part where synthetic resin in a molten state is solidified after a signal wire or the like is soldered. The synthetic resin part  16  covers a part where the first and second covering signal electric wires  23 - 1  and  23 - 2  and the drain wire  26  are soldered and connected to the terminal part at the Y 1  side of the relay board  12 , so that a solder connecting part  14  is reinforced. See Japanese Laid-Open Patent Application No. 2003-59593. 
   In the balanced transmission cable connector  10 , the clamp member  27  is fixed to the shield covers  31  and  32 . The balanced transmission cable connector  10  has a structure where even if the balanced transmission cable connector  10  is inserted into or pulled out from a socket of the computer so that the balanced transmission cable  20  is curved, there is no influence of the curve to an inside of the balanced transmission cable connector  10 , more specifically to the solder connecting part  14 . 
   However, the pair electric wires  21  are bound by a tube and therefore not fixed to each other. Accordingly, in a case where, for example, a clamp force by the clamp member  27  is not sufficient, if the balanced transmission cable  20  is pulled and curved, a pulling force of a certain pair electric wire  21  is transferred to even the inside of the balanced transmission cable connector  10  via the clamp member  27 . 
   The synthetic resin part  16  is situated on only the upper surface and the lower surface of the relay board  12 . Therefore, the pulling force transferred via the clamp member  27  reaches to the solder connecting part  14  covered by the synthetic resin part  16 , via the electric wire arranging member  15 . As a result of this, a stress is applied to the solder connecting part  14 . 
   SUMMARY OF THE INVENTION 
   Accordingly, it is a general object of the present invention to provide a novel and useful cable connector. 
   Another and more specific object of the present invention is to provide a cable connector whereby the strength of a solder connecting part to a relay board of a wire is improved. 
   The above object of the present invention is achieved by a cable connector, including: 
   a contact assembly body having a structure where a contact is provided in an electric insulating block body; 
   a relay board connected to the contact and provided at a back surface side of the contact assembly body; 
   an electric wire arranging member which is provided at an end side of the relay board and which is configured to arrange a plurality of covering electric wires extended from an end of a cable in an arranging direction of the contact; 
   wherein a wire which is extended from an end of an electric insulating covering part of the covering electric wire is provided at an end of the cable so as to mechanically and electrically connect to the relay board, 
   the electric wire arranging member has a synthetic resin receiving part configured to receive molten synthetic resin, 
   the synthetic resin receiving part is provided at a side facing a part connected to the wire, of the electric wire arranging member, 
   a synthetic resin part for reinforcing is formed into the synthetic resin receiving part by solidifying the molten synthetic resin, and 
   the synthetic resin part for reinforcing covers a part where the wire is connected, and fixes the end of the electric insulating covering part of the covering electric wire to the relay board. 
   According to the above-mentioned invention, the synthetic resin part for reinforcing is formed in the synthetic resin receiving part of the electric wire arranging member so as to cover a part where the wire is connected and fix an end part of the covering part of the covering signal electric wire to the relay board. Therefore, in a case where the cable is pulled and curved, even if a pulling force is transferred to the inside of the cable connector via the covering signal electric wire, the pulling force is securely received by the synthetic resin part for reinforcing which fixes the end part of the covering part to the relay board. Hence, it is possible to prevent the part where the wire is connected from being given influence. 
   Other objects, features, and advantages of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded perspective view of a related art balanced transmission cable connector  10 ; 
       FIG. 2  is a cross-sectional view of the balanced transmission cable connector  10  shown in  FIG. 1 ; 
       FIG. 3  is a cross-sectional view of a related art balanced transmission cable; 
       FIG. 4  is an exploded perspective view of a balanced transmission cable connector of a first embodiment of the present invention; 
       FIG. 5  is a cross-sectional view of the balanced transmission cable connector shown in  FIG. 4 ; 
       FIG. 6  is a view showing a state where pair electric wires provided at an end of the balanced transmission cable are arranged; 
       FIG. 7  is a first view for explanation of manufacturing processes of the balanced transmission cable connector shown in  FIG. 4 ; 
       FIG. 8  is a second view for explanation of manufacturing processes of the balanced transmission cable connector shown in  FIG. 4 ; 
       FIG. 9  is an exploded perspective view of a balanced transmission cable connector of a second embodiment of the present invention; 
       FIG. 10  is a cross-sectional view of the balanced transmission cable connector shown in  FIG. 9 ; 
       FIG. 11  is an exploded perspective view of a balanced transmission cable connector of a third embodiment of the present invention; and 
       FIG. 12  is a cross-sectional view of the balanced transmission cable connector shown in  FIG. 11 . 
   

   DETAILED DESCRIPTION OF THE PREFERED EMBODIMENTS 
   A description is given below, with reference to the  FIG. 4  through  FIG. 12 , of embodiments of the present invention. 
     FIG. 4  is an exploded perspective view of a balanced transmission cable connector  50  of a first embodiment of the present invention.  FIG. 5  is a cross-sectional view of the balanced transmission cable connector  50  shown in  FIG. 4 . In  FIG. 4  and  FIG. 5 , a direction of X 1 –X 2  shows a width direction of the balanced transmission cable connector  50 . A direction of Y 1 –Y 2  shows a longitudinal direction of the balanced transmission cable connector  50 . A direction of Z 1 –Z 2  shows a height direction of the balanced transmission cable connector  50 . A direction of Y 1  shows a rear direction and a direction of Y 2  shows a front direction. 
   As shown in  FIG. 4  and  FIG. 5 , the balanced transmission cable connector  50  has a structure where shield covers  51  and  52  cover a plug assembly body  60 , a relay board  70 , an electric wire arranging member  80  and an end part of the balanced transmission cable  20 . The balanced transmission cable connector  50  connects to the end part of the balanced transmission cable  20 . Roughly speaking, an area where a synthetic resin part  90  for reinforcing is formed of the balanced transmission cable connector  50  is different from the corresponding area of the cable connector shown  10  in  FIG. 1  and  FIG. 2 . 
   The contact assembly body  60  has an electric insulating block body  61 . A pair of a first signal contact  62  and a second signal contact  63  and a ground contact  64  are inserted in the block body  61  and arranged in the X direction in turn. A signal pattern and a ground pattern (not shown in  FIG. 4  and  FIG. 5 ) are formed on an upper surface and a lower surface of the relay board  70 . Respective signal patterns are arranged in parallel in the Y direction. The signal patterns  71  are situated at both ends of the not shown signal patterns. The relay board  70  is engaged with a Y 1  side of the contact assembly body  60 . Ends at the Y 1  side of the signal contacts  62  and  63  and the ground contact  64  are solder-attached to the signal patterns and ground pattern, respectively. 
   The electric wire arranging member  80  has a rectangular parallelepiped shape external configuration. A electric wire pair arranging part  81  configured to arrange the electric wire pair  21  is provided at the Y 1  side of the electric wire arranging member  80 . 
   A first concave part  82  and a second concave part  83  configured to engage with the relay board  70  are provided at the Y 2  side and ends of X 1  and X 2  sides of the electric wire arranging member  80 . 
   A third concave part  85  which functions as a synthetic resin receiving part is formed between the first concave part  82  and the second concave part  83 . The third concave part  85  is mainly formed by a Z 1  side flange part  86  and a Z 2  side flange part  87 . The third concave part  85  is a space forming part surrounded by a Z 1  side internal surface  85   a , a Z 2  side internal surface  85   b , and a Y 1  side bottom surface  85   c . An opening forming part  85   d  is formed at the Y 2  side of the third concave part  85 . 
   The third concave part  85  has a size sufficient to receive the relay board  70  in a state where signal wires  23 - 1  and  23 - 2  and a drain wire  26  are soldered. The length in the Z 1  direction of the third concave part  85  is longer than the surface at the Z 1  side of the first concave part  82  (second concave part  83 ) by z 1 . The length in the Z 2  direction of the third concave part is longer than a surface at the Z 2  side of the first concave part  82  (second concave part  83 ) by z 2 . The length in the Y 1  direction of the third concave part is longer than the surface at the Y 1  side of the first concave part  82  (second concave part  83 ) by y 1 . 
   The Y 1  side bottom surface  85   c  is an end surface at the Y 2  side of the pair electric wire arranging part  81 . A plurality of pairs of half arc parts facing in the Z directions are arranged in the electric wire pair arranging part  81 . A pair of the half arc parts facing in the Z directions form a configuration corresponding to a cross-sectional configuration of the electric wire pair  21  so that the position of the electric wire pair  21  passing through the half arc part is restrained. 
   Next, a structure of the balanced transmission cable connector  50  is discussed while manufacturing processes of the balanced transmission cable connector  50  are discussed. 
   Processed end parts of the balanced transmission cable  20  are passed through the electric wire pair arranging part  81  of the electric wire arranging member  80  from the Y 1  side so as to be arranged as shown in  FIG. 6 . The insulating covering parts  24 - 1  and  24 - 2  of first and second covered signal electric wires  22 - 1  and  22 - 2  are projected into the opening part  85   d.    
   First, the Y 1  end side of the relay board  70  connected to the contact assembly body  60  and the Y 2  end side of the electric wire arranging member  80  where the electric wire pair  21  are arranged are combined while the Y 1  end side of the relay board  70  is engaged with the first and second concave parts  82  and  83 . Next, the first and second signal wires  23 - 1  and  23 - 2  and the drain wire  26  are soldered to the terminal part  71  situated at the Y 1  side of the relay board  70 , so that provisional assembly body  100  is completed at a first step. End parts of the insulating covering parts  24 - 1  and  24 - 2  and an end part of the Y 1  side of the relay board  70  are inserted into the third concave part  85 . Here, a numerical reference  101  represents a solder connecting part. 
   Next, as shown in FIG.  7 -(B), the provisional assembly body  100  is set to a jig  150  for molding a synthetic resin part  90  (not shown in FIG.  7 -(B)) for reinforcing. The jig  150  includes an upper mold  151  having a fourth concave part  152  and a lower mold  155  having a fifth concave part  156 . By the jig  150 , the electric wire arranging member  80  of the provisional assembly body  100  and a part of the Y 1  side of the relay board  70  are put between the upper mold  151  and the lower mold  155 . As a result of this, cavity forming parts  160  and  161  surround parts of the first and second signal wires  23 - 1  and  23 - 2  and the drain wire  26 , which are solder-connected to the relay board  12  and the solder connecting part  101 . Furthermore, the cavity forming parts  160  and  161  communicate with the Z 1  side and Z 2  side, respectively, of the opening part  85   d.    
   Next, as shown in FIG.  8 -(C), a thermoplastic resin  159  such as polyimide, which is heated at approximately 100° C. and molten, is injected from holes of the upper mold  151  and the lower mold  155  by using syringes  157  and  158 . As a result of this, insides of the cavity forming parts  160  and  161  are filled with the molten thermoplastic resin  159 . Furthermore, the molten thermoplastic resin  159  enters into the opening part  85   d  so that the opening part  85   d  is filled with the molten thermoplastic resin  159 . In addition, parts at end sides of the first and second covering signal electric wires  22 - 1  and  22 - 2  are surrounded by the molten thermoplastic resin  159 . After the injected resin is cooled so as to have a normal temperature and be solidified, the synthetic resin part  90  for reinforcing is formed as shown in FIG.  8 -(D). 
   After the jig  150  is opened, as shown in FIG.  8 -(E), a provisional assembly body  120  at a second step where the synthetic resin part  90  for reinforcing is formed is picked up. The synthetic resin part  90  for reinforcing situated in a area  91  from a position P 1  of the relay board  70  which is further to the Y 2  side than a position P 2  of head ends of the first and second signal wires  23 - 1  and  23 - 2  and the drain wire  26  to a position P 4  which is the inner part of the opening part  85   d  of the electric wire arranging member  80 , via the solder connecting part  101  and a position P 3  of the head ends of the electrically insulating covering parts  24 - 1  and  24 - 2 . 
   Therefore, the solder connecting part  101  is covered with the synthetic resin part  90  for reinforcing. Furthermore, as shown in FIG.  5 -(B), the relay board  70 , the electric wire arranging member  80 , and the end parts of the covering parts  24 - 1  and  24 - 2  of the first and second covered electric signal wires  22 - 1  and  22 - 2  are fixed to each other. That is, the end parts of the covering parts  24 - 1  and  24 - 2  are fixed to both the relay board  70  and the electric wire arranging member  80 . The electric wire arranging member  80  is fixed to the relay board  70 . The electric wire arranging member  80  is fixed to the relay board  70 . 
   Last, as shown in  FIG. 5 , the shield covers  51  and  52  cover the provisional assembly body  110  at the second step and the clamp member  27  is engaged with the provisional assembly body  110 . As a result of this, the balanced transmission cable connector  50  is completed. In the cable connector  50 , by the synthetic resin part  90  for reinforcing, the end parts of the covering parts  24 - 1  and  24 - 2  are fixed to the relay board  70  and the electric wire arranging member  80 , and the electric wire arranging member  80  is fixed to the relay board  70 . 
   In a case where the balanced transmission cable  20  is pulled and curved during the use of the cable connector  50 , even if a pulling force of a certain electric wire pair  21  is transferred to even the inside of the balanced transmission cable connector  50  via the clamp member  27 , the pulling force is received by head end parts of the covering parts  24 - 1  and  24 - 2  of the first and second covered electric signal wires  22 - 1  and  22 - 2 , namely a front side of the solder connecting part  101 . Therefore, the pulling force does not reach the solder connecting part  101 . Furthermore, the arranging member  80  does not independently slide against the relay board  70 . A stress to the soldering part due to the arranging member  80  independently sliding against the relay board  70  does not occur. Therefore, the balanced transmission cable connector  50  has a higher reliability regarding the solder connection part  101  than the related art connectors. 
     FIG. 9  is an exploded perspective view of a balanced transmission cable connector  50 A of a second embodiment of the present invention.  FIG. 10  is a cross-sectional view of the balanced transmission cable connector  50 A shown in  FIG. 10 . A configuration of an electric wire arranging member  80 A of the cable connector  50 A is different from the configuration of the electric wire arranging member  80  of the cable connector  50  shown in  FIG. 4  and  FIG. 5 . Hence, a configuration of a synthetic resin part  90 A for reinforcing in the second embodiment is different from the configuration of the synthetic resin part  90  for reinforcing in the first embodiment. 
   The electric wire arranging member  80 A has a structure where the Z 1  side flange  86  and the Z 2  side flange  87  of the electric wire arranging member  80  shown in  FIG. 4  are removed and opening parts  85 Ae and  85 Af are formed at the Z 1  and Z 2  sides, respectively. The opening parts  85 Ae and  85 Af communicated the opening  85 Aa. The synthetic resin part  90 A for reinforcing has parts  90 Aa and  90 Ab which are projected in Z 1  and Z 2  directions, respectively, and which engage with the opening parts  85 Ae and  85 Af in addition to the opening  85 Aa. 
   As shown in FIG.  10 -(B), the relay board  70 , the electric wire arranging member  80 A, the end parts of the covering parts  24 - 1  and  24 - 2  of the first and second covered electric signal wires  22 - 1  and  22 - 2  are fixed each other. That is, the end parts of the covering parts  24 - 1  and  24 - 2  are fixed to both the relay board  70  and the electric wire arranging member  80 A. The electric wire arranging member  80 A is fixed to the relay board  70 . 
   Since the opening part  85 Ae and  85 Af are provided at the Z 1  and Z 2  sides, it is possible for the thermoplastic resin to enter into the electric wire arranging member  80 A. 
     FIG. 11  is an exploded perspective view of a balanced transmission cable connector  50 B of a third embodiment of the present invention.  FIG. 12  is a cross-sectional view of the balanced transmission cable connector  50 B shown in  FIG. 11 . The cable connector  50 B is different from the cable connector  50  shown in  FIG. 4  in that the cable connector  50 B does not have the relay board  70 . 
   The signal wires  23 - 1  and  23 - 2  and the drain wire  26  are directly soldered to the Y 1  side ends of the signal contacts  62 B and  63 B of the contact assembly body  60 B and the ground contact  64 B. A numerical reference  101 B is a solder connecting part. 
   The electric wire arranging member  80  is engaged and connected with arm parts  61 Ba situated at both sides of the block body  61 B. The synthetic resin  90 B for reinforcing covers the Y 1  side ends of the signal contacts  62 B and  63 B and the ground contact  64 B and the solder connecting part  101 B. The synthetic resin  90 B for reinforcing also fills inside of the third concave part  85  and covers end parts of the covering parts  24 - 1  and  24 - 2 . As shown in FIG.  12 -(B), the signal contacts  62 B and  63 B, the electric wire arranging member  80 , and the covering parts  24 - 1  and  24 - 2  of the first and second covering signal electric wires  22 - 1  and  22 - 2  are fixed to each other by the synthetic resin  90 B for reinforcing. That is, the end parts of the covering parts  24 - 1  and  24 - 2  are fixed to both the signal contacts  62 B and  63 B and the electric wire arranging member  80 . 
   Therefore, in a case where the balanced transmission cable  20  is curved during the use of the cable connector  50 B, even if a pulling force of a certain electric wire pair  21  is transferred to even the inside of the balanced transmission cable connector  50 B via the clamp member  27 , the pulling force is received by head end parts of the covering parts  24 - 1  and  24 - 2  of the first and second covered electric signal wires  22 - 1  and  22 - 2 . Therefore, the pulling force does not reach the solder connecting part  101 B. 
   Furthermore, the arranging member  80  does not independently slide against the signal contacts  62 B and  63 B and the ground contacts  64 B. A stress to the soldering part due to the arranging member  80  independently sliding against the contacts  62 B,  63 B and  64 B does not occur. Therefore, the balanced transmission cable connector  50 B has a higher reliability regarding the solder connection part  101 B than the related art connectors. 
   The present invention is not limited to these embodiments, but variations and modifications may be made without departing from the scope of the present invention. 
   For example, an electrical connection between the signal wires  23 - 1  and  23 - 2  and the drain wire  26  and mechanical equipment may be not related to soldering but also electrical welding. Furthermore, the present invention is not limited to the balanced transmission cable connector but can be applied to a cable connector where ends of normal cables are arranged for connecting. 
   This patent application is based on Japanese Priority Patent Application No. 2004-51973 filed on Feb. 26, 2004, and the entire contents of which are hereby incorporated by reference.