Patent Publication Number: US-9843143-B2

Title: Cable connector assembly having improved wire spacer

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a cable connector assembly, more particularly to an improved wire spacer or organizer thereof. 
     2. Description of Related Arts 
     U.S. Patent Application Publication No. 2015/0044886, published on Feb. 12, 2015, shows a cable connector assembly including a spacer. The spacer has a plurality of passageways extending through a front and rear surfaces thereof for receiving cable wires. The cable is further fixed by dispensing glues in the through holes. 
     With the separate and distinct passageways of the above spacer, a holding force of the cable wire to the passageway is not strong such that an inadvertent movement of the cable wire during manufacturing process may cause misaligned front ends of the cable, which impacts subsequent soldering process. 
     An improved wire spacer in a cable connector assembly is desired. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide an improved wire spacer in a cable connector for facilitating preparation of cable wires including a first type and a second type. 
     To achieve the above-mentioned object, a cable connector assembly comprises: a cable including a plurality of wires; and an electrical connector including a spacer positioning the cable, the spacer defining a front face and a rear face, a plurality of through holes positioning the wires, and a respective midfellow formed between every two adjacent through holes; wherein a notch is defined on the midfellow in the rear face to make the through holes in fluid communication. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a perspective view of a cable connector assembly in accordance with the present invention; 
         FIG. 2  is a partially exploded view of the cable connector assembly in  FIG. 1 ; 
         FIG. 3  is a further partially exploded view of the cable connector assembly in  FIG. 1 ; 
         FIG. 4  is an exploded view of the cable connector assembly in  FIG. 1 , but not including the mating member. 
         FIG. 5  is a partially exploded view of the cable connector assembly in  FIG. 4 , not including the mating member, but from a different perspective. 
         FIG. 6  is a perspective view of the cable of the cable connector assembly in  FIG. 1 ; 
         FIG. 7  is an exploded view of a mating member of the cable connector assembly in  FIG. 1 ; 
         FIG. 8  is a view similar to  FIG. 7 , but from a different perspective; 
         FIG. 9  is a perspective view of the fixing member of the cable connector assembly in  FIG. 1 ; 
         FIG. 10  is a view similar to  FIG. 9 , but from a different perspective; 
         FIG. 11  is a schematic cross-sectional view of the cable assembled to the fixing member; and 
         FIG. 12  is a enlarge view of the dotted line portion in  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 to 3 , a cable connector assembly, e.g., a plug connector assembly  100 , in accordance with the present invention for mating with a mating connector (not shown) comprises an electrical connector  200  and a cable  300  electrically connected to the electrical connector  200 . The electrical connector  200  includes a mating member  1 , an internal printed circuit board (PCB)  2  disposed behind and electrically connecting with the mating member  1 , a wire organizer or spacer  4  for positioning the cable  300 , an inner shell  5  cover on the mating member  1  and a conjugation segment of the cable  300 , a strain relief  6  integrally molded on the inner shell  5  and the outer cable  300 , and a outer shell  7  cover on the inner shell  5  and the strain relief  6 . The plug connector assembly  100  can be mated with the mating connector in two orientations. 
     Referring to  FIGS. 7 and 8 , the mating member  1  comprises an insulative housing  11 , a plurality of first contacts  12  arranged in two rows and spaced apart from each other in a vertical direction, a latch  13  disposed between the two rows of contacts  12  for latching with the mating connector, an insulative member  14  disposed behind the insulative housing  11 , a metal shell  15  covering the insulative housing  11  and the insulative member  14 , and a pair of grounding members  16  disposed on the insulative housing  11 . 
     The insulative housing  11  comprises a top wall  110 , a bottom wall  111  spaced apart from and parallel with the top wall  110 , a pair of side walls  112  connecting the top wall  110  and the bottom wall  111 , a receiving room  113  surround by the top, bottom, and side walls  110 ,  111 ,  112 , and the receiving room  113  is divided into a front portion  1132  having a front opening  1131 , and a rear portion  1134  having a rear opening  1133 . The top wall  110  defines a top recess  1100  in communication with the front portion  1132 . The bottom wall  111  defines a bottom recess  1110  in communication with the front portion  1132 . Each of the side walls  112  defines a side recess  1120  extending forwardly from a rear end of the insulative housing  11  but not through a front end of the insulative housing  11 . The side recesses  1120  are in communication with the front portion  1132  and the rear portion  1134  of the receiving room  113 . A number of slots  114  are defined on a front end of the top wall  110  and the bottom wall  111 . 
     Each of the contacts  12  comprises a front mating portion  121  extending forwardly into the front portion  1132  of the receiving room  113 , a rear mating portion  122  extending rearwardly, and an intermediate mounting portion  123  secured to the insulative housing  11 . The front mating portion  121  is to be mated with the mating connector and the rear mating portion  122  is to be mated with the PCB  2 . The front mating portions  121  of the two rows of contacts  12  are arranged face to face along the vertical direction. 
     The latch  13  comprises a base portion  131  extending along a transverse direction, a pair of latch beams  132  respectively extending forwardly from two opposite ends of the base portion  131 , a latch portion  133  extending from a front end of each latch beam  132  along a face to face direction, and a pair of extension arms  134  respectively extending rearwardly from the two opposite ends of the base portion  131 . An extension arm  134  on one side is in a lower plane relative to a plane that the base portion  131  located, and another extension arm  134  on the other side is in a higher plane relative to the plane that the base portion  131  located. The latch  13  is mounted into the insulative housing  11  through the rear opening  1133  of the rear portion  1134  of the receiving room  113 . The base portion  131  abuts forwardly against the internal wall and the latch beams  132  are received into the side recesses  1120 , respectively. At least a portion of each of the latch portions  133  projects into the front portion  1132  of the receiving room  113 . 
     The insulative member  14  cooperates with the insulative housing  11  to fix the latch  13 . The insulative member  14  comprises an insulative base portion  140 , a pair of extending portions  141  extending rearwardly from two opposite ends of the base portion  140 , two rows of through holes  142  spaced apart in the vertical direction and extending through the insulative base portion  140  along a front to rear direction, and a receiving groove  143  forms between the two rows of through holes  142 . The receiving groove  143  is communicated with the through holes  142 . Each of the extending portions  141  defines a mounting slot  1410  therethrough extending along a rear to front direction. The insulative member  14  is mounted to the insulative housing  11  along a rear to front direction. The contacts  12  are received in the two rows of the through holes  142 . The base portion  131  of the latch  13  is received into the receiving groove  143 , and the extension arm  134  is received in the corresponding mounting slot  1410 . The rear mating portions  122  of the contacts  12  extend through the insulative member  140  through the through holes  142 , respectively. 
     The metal shell  15  has a closed circumference that has a good seal performance, a good anti-EMI performance, etc. The closed circumference of the metal shell  15  could be manufactured by drawing a metal piece, bending a metal piece, die casting, etc. The metal shell  15  comprises a front end  151  for being inserted into the mating connector, a rear end  152  and a third transition portion  153  for connecting to the front end  151  and the rear end  152 . The shape of the rear end  152  is consistent with the insulative member  14 . A diametrical dimension of the front end  151  is smaller than a diametrical dimension of the rear end  152 . The rear end  152  comprises a pair of latch tabs  1520  projecting outwardly. 
     One of the grounding members  16  is received into the top recess  1100 , and the other one is received into the bottom recess  1110 . Each of the grounding members  16  comprises a flat body portion  160 , a pair of mounting portions  161  extending from two opposite ends of the flat body portion  160  and toward the insulative housing  11  for being attached to the insulative housing  11 , a front grounding tabs  162  extending forwardly from a front side of the flat body portion  160  and entering into the front portion  1132  of the receiving room  113 . The mounting portions  161  and the front grounding tabs  162  are received in the corresponding slots  114  of the top wall  110  and the bottom wall  111 . The front grounding tabs  162  are used for mating with the mating connector. The front grounding tabs  162  of the pair grounding members  16  are disposed face to face along the vertical direction. A distance along the vertical direction between the front grounding tabs  162  of the pair of grounding members  16  is greater than a distance along the vertical direction of the front mating portions  121  of the two rows of contacts  12 . 
     Referring to  FIGS. 4-5 , the PCB  2  is disposed between the mating member  1  and the cable  3 . The cable  300  is electrically connected with the contacts  12  by the PCB  2 . The PCB  2  comprises a front portion  21 , a rear portion  22 , and a middle portion  23  connecting the front portion  21  and a rear portion  22 . The PCB  2  defines a top side  24  and a bottom side  25  opposite to the top side  24 . A number of first conductive pads  210  are formed on both of the top side  24  and the bottom side  25  of the front portion  21 , and electrically connected to the rear mating portions  122  of the contacts  12 . A plurality of second conductive pads  220  are formed on both of the top side  24  and the bottom side  25  of the rear portion  22 , and electrically connected with a number of wires  30  of the cable  300 . A number of third conductive pads  221  are formed on a side of the second conductive pads  220  away from the first conductive pads  210 . The width of front portion  21  is smaller than the rear portion  22  along a transverse direction. The distance between the adjacent first conductive pads  210  is smaller than the adjacent second conductive pads  220 . The width of the first conductive pads  210  is greater than the second conductive pads  220 . The number of the first conductive pads  210  is greater than the second conductive pads  220 . A metal pad  230  is formed on both of the top side  24  and the bottom side  25  of the middle portion  23  for electrically connected with the corresponding extension arms  134  of the latch  13  to strengthen the fixation of the latch  13 . The PCB  2  is mounted to the insulative member  14  by the front portion  21  along the mounting slots  1410 . The front portion  21  of the PCB  2  is disposed between the rear mating portions  122  of the two rows of contacts  12 . The rear mating portions  122  are electrically connected with the corresponding first conductive pads  210 . A number of electrical components  26  are set on the PCB  2 . 
     Referring particularly to  FIG. 6  and  FIG. 11 , the cable  300  has a number of wires  30  and a sheath  33  that contains the wires  30 , e.g., two types of wires. Each wire  30  comprises a number of the first type of wires  31  and a number of second type of wires  32 . A number of the first type of wires  31  are set on at least one side of the PCB  2 , and a number of the second type of wires  32  are arranged adjacent to the first type of wires  31 . Each of the first type of wire  31  includes a first inner dielectric  311 , a inner jacket  312  covering the first inner dielectrics  311 , a braiding  313  covering the inner jacket  312  and a outer jacket  314  covering on the braiding  313 . The braiding  313  are electrically connected with the third conductive pads  221 . The second type of wires  32  includes a first wire  321  and a second wire  322 . Both of the first wire  321  and the second wire  322  includes a second inner dielectrics  323 , a first jacket  324  covering on the second inner dielectrics  323 . The second wire  322  further includes a second jacket  325  covering the first jacket  324 . The first jacket  324  of the second wire  322  is used to prevent burns of the second wire  322  when welding the braiding  313 . The first jacket  324  is made of Teflon insulation material which has a higher temperature resistance, that prevents a short circuit occurs when weld the braiding  313  to the third conductive pads  221 , although touching the first jacket  324 . The second jacket  325  is made of PET material which has a good adhesiveness, and difficult to shift after being fixed using glue. The first jacket  324  of the first wire  321  can be made of PET material or some other material has a good adhesiveness for making itself more firmly fixed by glue. In this embodiment, only the second type of wires  32  adjacent the first type of wires  31  on the top side  24  of the PCB  2  includes the second jacket  325 . A bare ground wire defining on the bottom side  25  is set on a side of the first type of wire  31 , while the other side of the first type of wire  31  is vacant, so it is unnecessary to use the second type of wires  32  having the second jacket  325 . In other embodiments, the second type of wires  32  can be set adjacent to the first type of wires  31  on the top side  24  and the bottom side  25  according to need. The second type of wires  32  are set on inside position of the PCB  2 , and the first type of wires  31  are set on both sides of the second type of wires  32 . In this embodiment, the number of the second type of wires  32  is seven, and the number of the first type of wires  31  is eight. In other embodiments, the first type of wires  31  and the second type of wires  32  can be provided in a different quantity according to needs. 
     Referring also to  FIG. 9  and  FIG. 10 , the spacer  4  according to present embodiment has two pieces, and in other embodiment, the spacer  4  can be one-piece. The spacer  4  in present embodiment comprises an upper half  41  and a lower half  42  cooperated with the upper half  41 . A part of the wires of the first and second types are positioned on the top side  24  of the PCB  2  by the upper half  41 , and the other parts of the wires of the first and second types are positioned on the bottom side  25  of the PCB  2  by the lower half  42 . Each spacer half has a front face  43  close to the PCB  2 , an opposite rear face  44 , a top face  45 , a bottom face  46 , a plurality of first through holes  471  for positing the first type of wires  31 , a plurality of second through holes  472  for positing the second type of wires  32 , and a plurality of midfellows or partitions  473  formed between the through holes. The midfellows  473  extend from the front face  43  to the rear face  44 . A notch  474  is defined on each of the midfellows  473  and extended from the rear face  44  along a rear to front direction but not through the front face  43 , to make the adjacent through holes in fluid communication. The wires  31  are posited in the corresponding through holes by pointing the glue into the through holes and letting the glue flow among the wires  30  through the notch  474 . The adhesion area of glue in the through holes increases, thereby increasing the holding force. The notch  474  extends forwardly but not through the front face  43 , which ensures the strength of the spacer  4  not reduced. Each of the first through holes  471  and the second through holes  472  includes a front portion  481  close to the front face  43 , a rear portion  482  close to the rear face  44 , and a middle portion  483  connecting the front portion  481  and the rear portion  482 . The diameter of the front portion  481  is smaller than the middle portion  483 , and the diameter of the middle portion  483  is smaller than the rear portion  482 . That makes the glue in the through holes easy to flow and diffuse. The rear portion  482  includes a first portion  484  close to the rear face  44  and a second portion  485  connecting with the middle portion  483 . The diameter of the first portion  484  is decreasing along a rear to front direction for facilitating glue penetration. An avoiding portion  49  communicating with the second through holes  472  is defined on each spacer half through the front face  43  and the top face  45 . The second type of wires  32  can be received in the avoiding portion  49  when the first type of wire  31  is handling to avoiding accidental injury. The second type of wires  32  extending from the second through holes  472  are connected with the PCB  2 . A recess of the avoiding portion  49  defines a number of limiting groove  461  to limit the horizontal movement of the wires  32  of second type. A respective step  490  is formed on each spacer half for engaging with a rear edge of the PCB  2 . A pair of posts  462  formed on the first half  41  or the second half  42  are extended from the two opposite end of the bottom face  46 , and the another of the spacer half defines a pair of receiving slots  463  to receive the corresponding posts  462 . 
     Referring particularly to  FIG. 3 , the inner shell  5  includes a first shell  51  and a second shell  52 . The first shell  51  has a closed circumference that has a good seal performance, a good anti-EMI performance, etc. The closed circumference of the first shell  51  could be manufactured by drawing a metal piece, bending and forming a metal piece, die casting, etc. The first shell  51  comprises a first front end  511  telescoped with a rear end of the mating member  1 , a first rear end  512  opposite to the first front end  511 , and a first transition portion  513  between the first front and rear ends  511  and  512 . The first front end  511  is larger than the first rear end  512 . The first front end  511  defines a pair of latch holes  5110  latched with the latch tabs  1520  of the metal shell  15 , when the first shell  51  is telescoped on an outer side of the rear end  152  of the metal shell  15 . A block  5120  is defined on each opposite side of the first rear end  512 . The first front end  511  of the first shell  51  is interference fit with the rear end  152  of the metal shell  15 . The first front end  511  of first shell  51  and the rear end  152  of the metal shell  15  are further connected by laser welding in some spots or full circumference to have a good strength. 
     The second shell  52  has a closed circumference that has a good seal performance, a good anti-EMI performance, etc. The closed circumference of the second shell  52  could be manufactured by drawing a metal piece, bending and forming a metal piece, die casting, etc. The second shell  52  comprises a second front end  521  telescoped with the first rear end  512  of the first shell  51 , a second rear end  522  telescoped and crimped with the cable  300 , and a second transition portion  523  between the second front end  521  and the second rear end  522 . The second front end  521  is larger than the second rear end  522 . In assembling, firstly, the second shell  52  is telescoped on the cable  300 . The second shell  52  is moved forwardly and telescoped on the spacer  4 , after the wires  31  and  32  are soldered on the second conductive pads  220 . A fixing hole  5210  are defined on the both side of the second front end  521 . Then, the second shell  52  is forwardly moved beyond the spacer  4  to latch with the first rear end  512  of the first shell  51 , and the block  5120  is received and fixed in the corresponding fixing hole  5210 . Because of the second front end  521  is telescoped on the first rear end  512 , the second front end  521  is larger, further avoiding the interference with the cable  300 . Because of the second front end  521  is telescoped on the first rear end  512 , the engagement of the first shell  51  and the second shell  52  is tightly, which achieves a good interference effect. The second front end  521  of second shell  52  and the first rear end  512  of the first shell  51  are further connected by spot laser welding or continuous welding to have a good strength. The second rear end  522  is telescoped on the cable  300  and riveted with the cable  300 . 
     In assembling the cable connector assembly  100 , firstly, the mating member  1  and the PCB  2  is provided, and the PCB  2  is assembled on the mating member  1 . The extension arms  134  of the latch  13  are soldered with the third conductive pads  230 . The cable  300  is provided. The cable  300  includes a number of first type and second type of wires. The times of processing the first type of wire  31  is more than the second type of wire  32 . Each of the first type of wires  31  includes a first inner dielectric  311 , a inner jacket  312  covering the first inner dielectric  311 , a braiding  313  covering the inner jacket  312  and a outer jacket  314  covering on the braiding  313 . The wires  32  of second type include first wires  321  and second wires  322 . The spacer  4  defining a first half  41  and a second half  42  is provided. The first type of wires  31  are inserted into the first through holes  471 , and the second type of wires  32  are inserted into the second through holes  472 . The second type of wires  32  are arranged adjacent to the first type of wires  31 . A portion of the cable  300  extending form the spacer  4  is securing by glue. Because of the outmost jacket of the second type of wires  32  is made of PET material with a good property of adhesion, the retaining force between the spacer  4  and the cable  300  is strong, and it is not easy to depart the cable  300  from the spacer  4  in assembly manufacturing process, and than, it avoids the length of inconsistencies when soldered effectively. The extended wires  32  of second type are bended rearwardly in the avoiding portion  49  to be out of way, i.e., not in the operation path of the first type of cable wires  31 . In present embodiment, the method of processing the wires  30  is laser cutting, but in other embodiments, it also can be other methods. The step of operating the extended cable wires  31  of the first type may comprise removing an outer jacket  314  to exposing the braiding  313 , and than removing the braiding  313  to exposing the inner jacket  312  thereof. The extended wires  32  of the second type is returned to its original state before bending and cut by the laser machine together with the first type of wires  31 , to remove the inner jacket  312  of the wires  31  of the first type and the first and second jacket  324 , 325  of the second type of wires  32 , as a result, the first inner dielectrics  311  of the first type of wires  31  and the second inner dielectrics  323  of the second type of wires  32  are exposed. Than the cable  300  are soldered on the PCB  2 , the first inner dielectrics  311  of the first type of wires  31  are connected to the second conductive pads  220  on the top side  24 , and the braiding  313  of the first type of wires  31  are connected to the third conductive pads  221 . The first jacket  324  is made of Teflon, which avoids the short-circuited effectively. The second inner dielectrics  323  are connected to the corresponding second conductive pads  220  on the bottom side  25 . 
     The inner shell  5  covers at least a portion of the mating member  1  and the cable  300 . 
     The strain relief  6  is molded on at least a portion of the inner shell  5  and the cable  300 . The outer shell  7  is molded or mounted on the inner shell  5  and the strain relief  6 , and fixed use glue.