Patent Description:
The present disclosure also relates to a connector for automotive applications and an assembly comprising such a connector. The connector is preferably usable for multi GHz applications. In particular, the disclosure relates to an H-MTD® connector and an assembly comprising such an H-MTD® connector.

The so called H-MTD® system is produced by a company called "Rosenberger Hochfrequenztechnik GmbH & Co. Connectors of said system are meant to allow data transmission up to <NUM> or <NUM> Gbps while having a small package size. Applications for the H-MTD® system are <NUM> camera systems, autonomous driving, radar, lidar, high-resolution displays and rear seat entertainment.

A method according to the preamble of claim <NUM> is known from <CIT>. Further prior art is disclosed in <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

There is a need for a simpler method of assembling a connector for automotive multi GHz applications and for such a connector that can be assembled more easily. Furthermore, there is a need for a connector and a method of assembling such a connector which allow less complicated quality control.

The present disclosure provides a method of assembling a connector for automotive applications, comprising the steps of: providing a cable having at least one inner conductor; connecting at least one elongated inner signal contact of the connector to a stripped end of the at least one inner conductor; surrounding the at least one elongated inner signal contact by an insulating element; placing a first shielding part of the connector around a first portion of the insulating element from a first radial direction; placing a second shielding part of the connector around a second portion of the insulating element from a second radial direction generally opposite to the first radial direction; and joining the first and second shielding parts to form a shielding contact of the connector surrounding the insulating element. The at least one elongated inner signal contact is connected to the stripped end of the at least one inner conductor by welding.

One basic idea is therefore to divide the outer shielding contact into at least two parts that can be easily joined together during assembly. This allows placing the at least two shielding contact parts around the at least one inner signal contact from a radial direction instead of having to plug the at least one inner signal contact into the outer shielding contact from an axial direction. It has been found that assembly and quality control are simplified by the above mentioned method.

The present disclosure further provides a connector for automotive applications, comprising at least one elongated inner signal contact, an insulating element surrounding the at least one elongated inner signal contact, a first shielding part and a second shielding part, wherein the first and second shielding parts together form a shielding contact surrounding the insulating element.

Such a connector is simpler to assemble while quality control during assembly is also simplified.

Embodiments are given in the subclaims, the description and the drawings.

According to an embodiment, the first and second shielding parts each form a half shell. Such a half shell can be easily manufactured by a stamped/bent part.

According to a further embodiment, the first shielding part and/or the second shielding part comprise(s) at least one contact spring. Preferably, the first shielding part and/or the second shielding part comprise(s) multiple contact springs, such as four or five contact springs. This improves the electrical and mechanical connection between the connector and a mating connector.

According to an embodiment, the at least one elongated inner signal contact is connected to the stripped end of the at least one inner conductor by laser welding. Laser welding has the advantage that the electrical connection is improved.

According to a further embodiment, the at least one inner conductor is connected to a second connection portion of the at least one inner signal contact forming a tube. In particular, the tube can define a cross-section that changes along the tubes axial direction, in particular regarding its size. Preferably, the tube can have cylindrical and/or conical shape.

According to an embodiment, an opening is formed in the tube. The opening <NUM> can be used to check whether a respective stripped end of the at least one inner conductor can be seen through the opening. Furthermore, the opening can be used for welding the stripped end of the at least one inner conductor to the at least one inner signal contact.

To improve data rate through the connector, the provided cable can have at least two inner conductors and the connector can have at least two elongated inner signal contacts which are connected to stripped ends of the at least two inner conductors.

In order to safe time during assembly, it is preferred that the elongated inner signal contacts are connected to the stripped ends of the inner conductors simultaneously. This can be done by building a special crimping tool or by welding the inner signal contacts to the stripped ends of the inner conductors simultaneously.

According to an embodiment, the first and second shielding parts are joined by crimping and/or welding, in particular crimping and laser welding. Using both crimping and welding has the advantage than crimping can be used for pre-assembling the two parts and welding can then be used to finalize the connection between the first and second shielding parts.

One option how to surround the at least one elongated inner signal contact by the insulating element is by snapping the insulating element onto the at least one elongated inner signal contact so that a form-fit connection is established between the insulating element and the at least one elongated inner signal contact. Preferably, the insulating element is connected to the at least one elongated inner signal contact by axially inserting the at least one inner signal contact into at least one channel or opening of the insulating element until an elastically deformable part of the insulating element engages behind a locking surface of the at least one inner signal contact.

A second option how to surround the at least one elongated inner signal contact by the insulating element is to form the insulating element out of a first and a second insulating part that are joined together during assembly. In this embodiment, the at least one elongated inner signal contact is surrounded by the insulating element by placing the first insulating part around a peripheral portion of the at least one elongated inner signal contact from a first, in particular axial, direction and by placing the second insulating part around a remaining peripheral portion of the at least one elongated inner signal contact from a second, in particular radial, direction different from the first direction. The second insulating part can comprise a locking surface which engages with a locking surface of the at least one inner signal contact to limit or prevent axial movement of the at least one inner signal contact relative to the insulating element.

A third option how to surround the at least one elongated inner signal contact by the insulating element is to overmold the at least one elongated inner signal contact with an insulating material to form the insulating element. If the at least one elongated inner signal contact is formed as a tube, it should be made sure that the inner space of the tubes is not filled up with mold.

Overmolding the at least one elongated inner signal contact with an insulating material to form the insulating element can be done before the at least one elongated inner signal contact is connected to respective conductors of a cable. In this case, the portions of the at least one elongated inner signal contact that are connected to the wires, e.g. the crimping or welding portions of the at least one elongated inner signal contact, should not be overmolded.

In order to better secure a mechanical and/or electrical connection between the first and second shielding parts, an outer cover can be positioned around the first and second shielding parts. The cover can form a closed circumference around the first and second shielding parts. The first and second shielding parts can have one or multiple connecting wings that are in contact with an inner peripheral surface of the cover to mechanically hold the connecting wings in place and/or electrically connect the first and second shielding parts with the cover. Preferably at least one of the connecting wings is biased against the cover to secure an electrical connection between the at least one of the first and second shielding parts and the cover.

According to an embodiment, the outer cover comprises a first and a second cover part. The first cover part is positioned around a portion of the first shielding part and around a portion of the second shielding part from a third radial direction different from the first and second radial directions. Similarly, the second cover part is positioned around a portion of the first shielding part and around a portion of the second shielding part from a fourth radial direction. The fourth radial direction can be located generally opposite to the third radial direction.

According to the invention, at least one of the first and second shielding part is molded over by an electrically insulating material. In particular, the first and the second shielding part can be partially overmolded by an electrically insulating material. An inner and/or outer surface of the first and/or second outer shielding part can be overmolded. In particular, an inner surface of the first and/or second outer shielding part can be partially overmolded such that a rib is formed on an inner side of the at least one of the first and second shielding parts for electrically insulating the two inner conductors from one another. According to the invention, edges of the insulating material are formed on an outer side of the at least one of the first and second shielding parts for locking the connector in a connector housing and/or by a TPA (terminal position assurance). In other words, the insulating material can form first and second locking means that correspond to first and second locking means of a connector housing.

According to an embodiment, the step of surrounding the at least one elongated inner signal contact by the insulating element is performed before the step of connecting the at least one elongated inner signal contact to the stripped end of the at least one inner conductor. In other words, the at least one elongated inner signal contact and the insulating element are pre-assembled before connecting them to the at least one stripped end of the at least one inner conductor. Alternatively, the step of surrounding the at least one elongated inner signal contact by the insulating element can be performed after the step of connecting the at least one elongated inner signal contact to the at least one stripped end of the at least one inner conductor.

According to an embodiment, the connector is a female connector. Alternatively, the connector can be a male connector. The at least one elongated inner signal contact can comprise a first connection portion and/or a second connection portion generally formed as a tube.

According to a further aspect, an assembly comprising a connector with one or more of the aforementioned or afterwards mentioned features connected to a shielded cable, e.g. a shielded-twisted-pair cable or a shielded-parallel-pair cable is provided. Using the connector with a shielded-twisted-pair cable or a shielded-parallel-pair cable allows transferring data in a vehicle with a high data rate.

According to an embodiment, multiple elongated inner signal contacts are each crimped and/or welded to wires of the shielded-twisted-pair cable or the shielded-parallel-pair cable.

Exemplary embodiments and functions of the present disclosure are described herein in conjunction with the following drawings, showing:.

<FIG> depicts an exploded view of a connector <NUM>, in particular a female connector, comprising two elongated inner signal contacts <NUM> arranged generally parallel to each other along a plug or axial direction <NUM> of the connector <NUM>. The signal contacts <NUM> have a first connection portion <NUM> for connecting the connector <NUM> to a mating connector, in particular a mating male connector, and a second connection portion <NUM> for connecting the signal contacts <NUM> to respective conductors or wires <NUM> of a cable <NUM>. The second connection portion <NUM>, as depicted by the two alternatives shown in <FIG>, can be formed as a crimping portion 18a having two crimping wings <NUM> or can be formed as a welding portion 18b having a welding opening <NUM>. The welding opening <NUM> can be used to connect the signal contacts <NUM> to respective conductors or wires <NUM> of the cable <NUM> via laser welding. Alternatively, resistance welding can be used to connect the signal contacts <NUM> to respective conductors or wires <NUM> of the cable <NUM>.

Around the inner signal contacts <NUM> an insulating element <NUM> which can be called di-electric housing is arranged. In the embodiment shown in <FIG>, the insulating element <NUM> is made out of two separate parts 28a and 28b. The first and second parts 28a and 28b of the insulating element <NUM> are attachable to each other by a click-on connection, i.e. a snap fit engagement. The second part 28b fulfills the task of locking the signal contacts <NUM> in an axial direction so that the inner signal contacts <NUM> remain in their axial position when the connector <NUM> is connected to a mating connector. A more detailed explanation of this feature will be given in regard to <FIG>.

The connector <NUM> further comprises a first shielding part <NUM> and a second shielding part <NUM> both formed as half shells which together form an outer shielding contact <NUM>. The outer shielding contact <NUM> surrounds the inner signal contacts <NUM> and the insulating element <NUM> to provide a shield against interfering signals. However, the outer shielding contact <NUM> can also be used as an electrical conductor to transport electric power. At a distal end <NUM> of the connector <NUM>, the outer shielding contact <NUM> comprises multiple shielding contacts <NUM> which are discussed in more detail regarding <FIG>. At a proximal end <NUM> of the connector <NUM>, the first shielding part <NUM> forms a cover <NUM> which is discussed in more detail in regard to <FIG>. The second shielding part <NUM> forms a crimping portion <NUM> at the proximal end <NUM> of the connector <NUM> to mechanically and electrically connect the outer shielding contact <NUM> to the cable <NUM>. Furthermore, the first and second shielding parts <NUM>, <NUM> each disclose wings <NUM>, <NUM> to create an inner shield <NUM> and an outer shield <NUM> overlapping the inner shield <NUM>. A more detailed description of the inner and outer shield <NUM>, <NUM> is given in regard to <FIG>.

In order to better secure the connection between the first shielding part <NUM> and the second shielding part <NUM>, a cover <NUM> comprising a first cover part <NUM> and a second cover part <NUM> are placed around the first and second shielding parts <NUM>, <NUM> and are connected to each other, in particular via a click-on connection. The first and second cover parts <NUM>, <NUM> have a C-shaped cross section so that they can each be placed around a half of the first shielding part <NUM> and the second shielding part <NUM>. Furthermore, the connector <NUM> comprises an inner crimp ferrule <NUM> which is placed around the cable <NUM>.

<FIG> depict an assembly instruction for the connector <NUM> of <FIG>. In a first step, the inner crimp ferrule <NUM> is crimped onto the cable <NUM>. The inner crimp ferrule <NUM> has a first portion 60a that is crimped around portion 22a of the cable <NUM> where a protection layer <NUM> is the outermost layer of the cable <NUM>. The inner crimp ferrule <NUM> further has a second part which is formed around a portion 22b of the cable <NUM> where a shield layer <NUM> of the cable <NUM> is the outermost layer of the cable <NUM>, i.e. where the protection layer <NUM> has been removed. After the inner crimp ferrule <NUM> is connected to the cable <NUM>, the shield layer <NUM> is folded backwards over the inner crimp ferrule <NUM>. Additionally, end sections 22c of the cable <NUM> are stripped so that the conductors or wires <NUM> of the cable <NUM> are not surrounded by insulation material anymore. In the next step, the inner signal contacts <NUM> are connected to the stripped sections 22c of the wires <NUM>. While the inner signal contacts <NUM> are connected via crimping in the shown embodiment, the electrical connection between the inner signal contacts <NUM> and the wires <NUM> can be improved if the connection is established by welding, in particular laser welding. To improve cycle time of this connecting step, the two inner signal contacts <NUM> can be connected to the stripped sections of the wires <NUM> simultaneously.

After the inner signal contacts <NUM> are attached to the wires <NUM>, the first part 28a of the insulating element <NUM> is put on the inner signal contacts <NUM> from the axial direction <NUM> so that the inner signal contacts <NUM> are assimilated in axial channels <NUM> of the first part 28a of the insulating element <NUM>. Then, the second part 28b of the insulating element <NUM> is clicked on the first part 28a of the insulating element <NUM> from a radial direction. Thereby, the inner signal contacts <NUM> are axially fixed to the insulating element <NUM>.

After the insulating element <NUM> is connected to the inner signal contacts <NUM>, the first shielding part <NUM> is placed onto a section extending from a distal end of the insulating element <NUM> to a section of the cable <NUM> where the shield layer <NUM> is folded backwards onto the protection layer <NUM> of the cable <NUM>. In order to connect the first shielding part <NUM> to the insulating element <NUM>, the first shielding part <NUM> comprises two connecting wings <NUM> which are bent around the insulating element <NUM> in order to radially fixate the first shielding part <NUM> onto the insulating element <NUM>. For axial fixation of the first shielding part <NUM>, blocking elements <NUM> are formed on an outer surface of the insulating element <NUM>. The blocking elements <NUM> engage with the connecting wings <NUM> in order to limit or prevent axial movement of the first shielding part <NUM>. Furthermore, in a section of the cable <NUM> right before the distance between the wires <NUM> is increased, the shielding wings <NUM> are placed onto the cable <NUM> and bent almost all the way around the wires <NUM> and their respective insulation (cf. By placing the first shielding part <NUM> onto the insulating element <NUM> and the cable <NUM>, the cover <NUM> comes into contact with the back-folded portion of the shield layer <NUM>.

For simplifying explanation of the method of assembling, the assembly is turned in the figures. However, this is not a necessary step in production.

After the first shielding part <NUM> is securely fixed to the insulating element <NUM> and the cable <NUM>, the second shielding part <NUM> is attached to the assembly from an opposite radial side. The second shielding part <NUM> comprises connecting wings <NUM> which are bent around the first shielding part <NUM> to radially fixate the second shielding part <NUM> onto the first shielding part <NUM>. A groove <NUM> extending perpendicular to the axial direction <NUM> is formed on the outer surface of the first shielding part <NUM> into which the connecting wings <NUM> of the second shielding part <NUM> are placed. Thereby, the second shielding part <NUM> is axially fixated onto the first shielding part <NUM>. Additionally, a rather smooth outer surface of the shielding contact <NUM> is generated.

The second shielding part <NUM> further comprises the wings <NUM> which are positioned in a corresponding axial section to the section of the wings <NUM>. In order to establish a so called "EMC-labyrinth", i.e. a shield where interference signals run dead, the second wings <NUM>, same as the wings <NUM>, are bent so that they surround the respective section of the cable <NUM> almost completely. Since the first and second shielding parts <NUM>, <NUM> are placed around the cable from opposite sides, gaps <NUM>, <NUM> (cf. <FIG>) which are present at least in an axial section between peripheral end sections 46a, 46b, 48a, 48b of the wings <NUM>, <NUM> are positioned on opposite sides of the cable <NUM>.

The second shielding part <NUM> also comprises the crimping portion <NUM> which is arranged in a corresponding axial section to the section of the cover <NUM> of the first shielding part <NUM>. The crimping portion <NUM> comprises two crimp wings 44a, 44b which are bent around the cable <NUM> and the cover <NUM> of the first shielding part <NUM>. The crimp wings 44a, 44b define corresponding peripheral ends 45a, 45b. The cover <NUM> is helpful to hold the shield layer <NUM>, usually a braid, down while the crimp wings 44a, 44b are bent around the cable <NUM>. It has been found that providing such a cover <NUM> improves production quality and robustness against cable abuse.

After the second shielding part <NUM> is fixated on the first shielding part <NUM>, the cover <NUM> is placed around the first and second shielding parts <NUM>, <NUM> to secure the connection between the first and second shielding parts <NUM>, <NUM>. The cover <NUM>, as mentioned before, comprises two parts: the first cover part <NUM> and the second cover part <NUM>. The first cover part <NUM> is positioned around portions of the first and second shielding parts <NUM>, <NUM> from a radial direction different from the directions from which the first and second shielding parts <NUM>, <NUM> are placed onto the assembly. The second cover part <NUM> is also positioned around portions of the first and second shielding parts <NUM>, <NUM> from a radial direction different from the directions from which the first and second shielding parts <NUM>, <NUM> and the first cover part <NUM> are placed onto the assembly. In particular, the first and second cover parts <NUM>, <NUM> are placed onto the first and second shielding parts <NUM>, <NUM> from opposite radial directions. In order to connect the first and second cover parts <NUM>, <NUM> together, connecting means are provided at the first and second cover parts <NUM>, <NUM>, in particular snap fit engagement means.

After the first and second cover parts <NUM>, <NUM> are connected to each other, the first and second shielding parts <NUM>, <NUM> are welded together at welding positions <NUM>. Then, the connector <NUM> is inserted into a connector housing <NUM>, in particular a female connector housing. The shown connector housing <NUM> is compliant to the standards set for the above mentioned H-MTD® system. In order to attach the connector housing <NUM> to the connector <NUM>, the connector housing <NUM> comprises terminal position assurance (TPA) <NUM> in form of a pusher. The pusher <NUM> is pushed radially into the connector housing <NUM> to axially connect the connector housing <NUM> to the connector <NUM>.

<FIG> depicts an assembly instruction for a connector <NUM> according to a second embodiment. According to the assembly method, the inner signal contacts <NUM> are axially inserted into the insulating element <NUM>. In this example, the insulating element <NUM> is formed as a single integral part. In the insulating element <NUM>, two axially extending passage openings <NUM> are formed which receive the inner signal contacts <NUM>. The inner signal contacts <NUM> can be axially fixated on the insulating element <NUM> by a snap-lock connection as shown in <FIG>. The inner signal contacts <NUM> can alternatively or additionally be axially fixated on the insulating element <NUM> by hooks <NUM> (<FIG>) or dimples formed on the inner signal contacts <NUM> and interfering with the insulating element <NUM>. An insertion depth controlled by an assembly machine can be used to make sure that both inner signal contacts <NUM> are inserted the same distance into the insulating element <NUM>. After the inner signal contacts <NUM> are pre-assembled with the insulating element <NUM>, the inner signal contacts <NUM> are connected to the wires <NUM> by laser or resistance welding.

After the inner signal contacts <NUM> are connected to the wires <NUM>, a first shielding part <NUM> is placed around the insulating element <NUM> and the cable <NUM>. However, compared to the assembly process described regarding <FIG>, the shielding part <NUM> placed first around the insulating element <NUM> has the crimp wings 44a, 44b. A second difference between the assembly processes is that the first shielding part <NUM> in <FIG> has an insulating layer 82a which was molded over a section of the first shielding part <NUM>. The insulating layer 82a comprises a rib <NUM> which is placed between the two wires <NUM> of the cable <NUM> to establish a further insulation between the wires <NUM>. After the first shielding part <NUM> is placed around the insulating element <NUM> and the cable <NUM>, a second shielding part <NUM> is also placed around the insulating element <NUM> and the cable <NUM>. The second shielding part <NUM> also has as an insulating layer 82b which was molded over a section of the second shielding part <NUM>. As can be seen in <FIG>, the insulating layers 82a and 82b together form an insulating layer <NUM> formed on the inside an the outside of the first and second shielding parts <NUM>, <NUM>. This insulating layer <NUM> allows forming multiple quality control elements <NUM> which can be used to evaluate whether the first and second shielding parts <NUM>, <NUM> are joined together correctly and whether the wires <NUM> and/or the insulating element <NUM> are located in the right place.

After placing the second shielding part <NUM> onto the first shielding part <NUM>, the crimp wings 44a, 44b of the first shielding part <NUM> are crimped around the cover <NUM> of the second shielding part <NUM> and the first and second shielding parts <NUM>, <NUM> are connected to each other via laser welding.

<FIG> and <FIG> depict options how to group multiple connectors <NUM> together. In <FIG> a connector collector housing <NUM> is shown that is connected to two female connectors <NUM>. The cover parts <NUM>, <NUM> or the insulating layers 82a and 82b (<FIG>), in particular their rear edges <NUM>, can be used to securely lock the connectors <NUM> within the collector housing <NUM>. In particular, they can be used to enably a primary and secondary lock of the connector <NUM> in the housing <NUM>. Using such a connector collector housing <NUM> allows faster assembly of an electrical wiring harness of a car. In <FIG>, a connector collector housing <NUM> capable of taking up four connectors <NUM> arranged in two lines and <NUM> rows is shown. This connector housing <NUM> allows connecting four cables <NUM> to mating cables at once.

<FIG> depict a section of the connector <NUM> where wings <NUM>, <NUM> of the first and second shielding parts <NUM>, <NUM> are located. <FIG> shows a cross sectional view of the above mentioned section along the dashed line shown in <FIG>. In an inner region of the connector <NUM>, two insulated conductors or wires <NUM> extend generally parallel to each other. Around the wires <NUM>, the inner shield <NUM> is formed by the wings <NUM> of the first shielding part <NUM>. The inner shield <NUM> almost completely surrounds the wires <NUM>. Only a small gap <NUM> is left between the peripheral ends 46a, 46b. As can be seen from <FIG>, the gap <NUM> is smaller than a distance between outer surfaces of the conductors <NUM>. At an opposite side of the gap <NUM>, an embossment <NUM> is formed so that the inner shield <NUM> extends into a free space between insulations of the two wires <NUM>. One could say that the inner shield <NUM> therefore has a cross sectional shape similar to two scuba tanks or scuba glasses. Around the inner shield <NUM>, the outer shield <NUM> is formed. The outer shield <NUM> has a similar general shape as the inner shield <NUM> but it has a larger diameter. Therefore, a second gap <NUM> is present between the peripheral ends 48a, 48b of the wings <NUM>. The gap <NUM> between the peripheral ends 48a, 48b of the wings <NUM> is located at the angular position of the embossment <NUM> formed in the wing <NUM>. On the other hand, the outer shield <NUM> also forms an embossment <NUM> which is located at the angular position of the gap <NUM> of the inner shield <NUM>. The two shields <NUM>, <NUM> create an "EMC-labyrinth" which provides improved shielding to the wires <NUM> against interfering signals.

At an axial beginning and an axial end of the section where wings <NUM>, <NUM> of the first and second shielding parts <NUM>, <NUM> are located, namely the tunnel in tunnel section, the gaps <NUM> and <NUM> are closed by the embossment <NUM> being in contact with the wings 46a and 46b. The wings 46a and 46b can be pushed against the embossment <NUM> by mounting the cover part <NUM> onto the first and second outer shielding contacts <NUM>, <NUM>. In order to make sure that the embossment <NUM> is in contact with the wings 46a and 46b only at the axial beginning and the axial end of the tunnel in tunnel section, the embossment can be larger and/or higher at the axial beginning and the axial end in comparison to a middle section of the embossment. As such, a return current which flows on the outer shielding contact <NUM> does not need to make any detours and can remain running in parallel and close by the signal currents.

<FIG> depict a section of the connector <NUM> where the first and second shielding parts <NUM>, <NUM> are connected to the cable <NUM>. In a center of the cross-section depicted in <FIG>, two insulated wires <NUM> are shown. Around the wires <NUM>, a foil <NUM> is arranged. Then, the shield layer <NUM> of the cable <NUM> is arranged around the foil <NUM>. The shield layer <NUM> of the cable <NUM> is formed as a braid. Around the shield layer <NUM>, the protection layer <NUM> of the cable <NUM> usually forming the outmost layer of the cable <NUM> is arranged. In the section shown in <FIG>, the inner crimp ferrule <NUM> is attached to the outer surface of the protection layer <NUM>. The shield layer <NUM> is folded backwards onto the inner crimp ferrule <NUM>. On top of the back-folded shield layer <NUM>, in a top section of the cable, the cover <NUM> of the first shielding part <NUM> is placed. On top of the cover <NUM> and the back-folded shield layer <NUM>, the crimping portion <NUM> of the second shielding part <NUM> is placed. As can be seen from <FIG>, the peripheral ends 45a, 45b of the crimp wings 44a, 44b of the second shielding part <NUM> are placed in an angular section where the cover <NUM> covers the shield layer <NUM>. Hence, the shield layer <NUM> is protected from the peripheral ends 45a, 45b of the crimp wings 44a, 44b.

<FIG> depicts a distal end of the connector <NUM> according to a first embodiment. The shielding contact <NUM> is formed from the first and second shielding parts <NUM>, <NUM>. A distal end portion of the first and second shielding parts <NUM>, <NUM> is mirror symmetrical so that the opposite side not shown in <FIG> of said distal end portion looks the same. The shielding contact is oval and thus has two longer sides and two shorter sides. At the longer sides, a first group 38a of shielding contacts <NUM> are positioned which generally extend in the axial direction <NUM> and are elastically deformable in a radial direction. At the shorter side of the connector <NUM>, a second group 38b of shielding contacts <NUM> is formed on the shielding contact <NUM>. The second group 38b of shielding contacts <NUM> consists of four shielding contacts 38b which each comprise two U-shaped portions <NUM>. The U-shaped portions <NUM> are design so that the bottom part of each U-shaped portion <NUM> is closest to the insulating element <NUM> arranged at an inside of the shielding contact <NUM>. The second group 38b of shielding contacts <NUM> is connected via a distal ring element <NUM>. The distal ring element <NUM> is formed of two ring segments, each connecting two second group shielding contacts 38b of the respective first and second shielding part <NUM>, <NUM>. The distal ring element <NUM> holds the first group 38a of shielding contacts <NUM> in a pre-loaded position, i.e. the first group 38a of shielding contacts <NUM> push against an inner side of the distal ring element <NUM>. This allows plugging the connecter <NUM> into a mating connector needing less force. The distal ring element <NUM> also prevents that ends of the shield contacts 38a can get caught by another element and be pulled outwards and thus be damaged. Furthermore, each of the shielding contacts <NUM> has a defined contact point <NUM> which is defined by an elevation at the outer surface of the respective contact <NUM>. In order to lower the needed force to plug in the connector <NUM> in a mating connector, some of the contact points <NUM> are axially spaced apart from other contact points <NUM>. In particular, contact points 94a of the first group 38a of shielding contacts <NUM> are axially distanced from contact points 94b of the second group 38b of shielding contacts <NUM>. In the embodiment shown in <FIG>, the first group 38a of shielding contacts <NUM> has two separate types of shielding contacts 38a, wherein the first type of shielding contacts 38a, the two inner shielding contacts, has contact points 94a which are axially distanced from contact points of the second type of shielding contacts 38a, the two outer shielding contacts.

<FIG> depicts a distal end of the connector <NUM> according to a second embodiment. Instead of having a first group 38a of shielding contacts <NUM> having four upper contacts and four lower contacts 38a, the connector <NUM> has a first group 38a of shielding contacts <NUM> which consists of five upper contacts 38a and five lower contacts 38a. One of the first group 38a of shielding contacts <NUM> on each of the sides, the shielding contact 38a in the middle of the five shielding contacts <NUM>, is designed as a sacrificial contact. Compared to the embodiment of <FIG>, the distal ring element <NUM> of <FIG> is a closed ring element, i.e. the ring segments are connected to each other, e.g. by laser welding.

In both embodiments shown in <FIG>, the plurality of shielding contacts 38a, 38b are arranged symmetrically and generally equally distanced from each other. The plurality of shielding contacts 38a, 38b is integrally formed with their respective first or second shielding part <NUM>, <NUM>. The segments of the distal ring element <NUM> are also integrally formed with their respective first or second shielding part <NUM>, <NUM>. The first and second shielding parts <NUM>, <NUM> can be made from sheet-metal and can be designed as a stamped/bent part.

<FIG> depict an embodiment, wherein an outer crimping tube <NUM> is put on the crimping portion <NUM>. In comparison to the cross-sectional view shown in <FIG>, in the cross-sectional view of <FIG>, there is additionally shown the outer crimping tube <NUM>. The outer crimping tube <NUM>, as is shown in <FIG>, can be put on the crimping portion <NUM> from a cable-side instead of a connector-side. Alternatively, a shrink tube (not shown), i.e. an elastic tube which shrinks when heat is being applied to it, can be used to cover the crimping portion <NUM>.

<FIG> depict the inner signal contacts <NUM> according to a first embodiment. The two elongated inner signal contacts <NUM> generally extend parallel to one another. Each inner signal contact <NUM> has a first connection portion <NUM> for connecting the signal contact <NUM> to a mating signal contact and a second connection portion <NUM> for connecting the signal contacts <NUM> to a respective wire <NUM> of a cable <NUM>. Each of the first connection portions <NUM> is formed as a tube having a first center axis <NUM>. Alternatively, the first connection portions <NUM> can comprise a solid pin welded into a stamped and rolled rear section to form male signal contacts. Each of the second connection portions <NUM> define a second center axis <NUM> where a center axis of the cable is placed at. A distance A between the center axes <NUM> of the first connection portions <NUM> is larger than a distance B between the center axes <NUM> of the second connection portions <NUM>. Alternatively, a distance between the center axes of the first connection portions can be smaller than a distance between the center axes of the second connection portions. In other words, the inner signal contacts <NUM> are formed so that a pitch translation is generated.

Each of the two inner signal contacts <NUM> are formed so that the first center axis <NUM> is spaced apart in parallel from the second center axis <NUM>. In order to achieve this feature, sections <NUM> of the inner signal contacts <NUM> extend into a direction oblique to the axial direction <NUM>. For example, the sections <NUM> can be formed by flat sheet metal or by a tube-shaped cross section. <FIG> depicts the inner signal contacts <NUM> inserted in the insulating element 28a of <FIG>.

<FIG> depict inner signal contacts <NUM> according to a second embodiment. The inner signal contacts <NUM> differ from the inner signal contacts <NUM> of <FIG> in that hooks <NUM> are formed at side surfaces of the flat sections <NUM>. Hence, the inner signal contacts <NUM> can be inserted into an insulating element <NUM> as shown in <FIG> and <FIG> and can be axially fixated by the hooks <NUM>. Furthermore, in the second connection portions <NUM> of the inner signal contacts <NUM>, welding openings <NUM> are formed at an upper side so that the inner signal contacts <NUM> can be easily connected to the wires <NUM> of the cable <NUM> via welding, e.g. laser or resistance welding. Alternatively, not shown crimping wings <NUM> can be formed at the second connection portions <NUM> so that the inner signal contacts <NUM> can be crimped onto the wires <NUM> of the cable <NUM>.

<FIG> depict the insulating element <NUM> according to another embodiment. Here, the insulating element <NUM> is manufactured by overmolding the inner signal contacts <NUM>. In order to make sure that the mold does not enter into the tubular first and second connection portions <NUM>, <NUM>, the tubular portions are sealed during the molding process. Similarly, the welding openings <NUM> or crimping wings <NUM> are not overmolded to be able to connect the inner signal contacts <NUM> to wires <NUM> of the cable <NUM> later on.

Instead of overmolding both inner signal contacts <NUM> together, it is possible to overmold each inner signal contact <NUM> individually and later join the two inner signal contacts <NUM>.

<FIG> depict two different possibilities on how to lock the inner signal contacts <NUM> in the insulating element <NUM>. According to a first embodiment shown in <FIG>, the insulating element <NUM> comprises a locking element <NUM> in form of an elastically deformable element which creates a snap fit connection between the inner signal contacts <NUM> and the insulating element <NUM> in the axial direction <NUM>. The locking element <NUM> has a first locking surface <NUM> which comes into contact with a second locking surface <NUM> of the inner signal contacts <NUM> by snapping back from a deformed position into a neutral position in a radial direction. This embodiment allows manufacturing the insulating element <NUM> as a <NUM>-piece part, e.g. by molding.

Contrary thereto, in the embodiment shown in <FIG>, the locking element <NUM> is a solid part 28b which is not formed integrally with the remaining insulating element <NUM> - as is shown in <FIG> -, but instead, the insulating element <NUM> is made out of two separate parts 28a, 28b as is shown in <FIG>. The second part 28b of the insulating element <NUM> functions as the locking element <NUM> and thus comprises the first locking surface <NUM> which comes into contact with the second locking surface <NUM> of the inner signal contacts <NUM>, in particular when the connector <NUM> is plugged into a mating connector. Once the outer shielding contact <NUM> is assembled, the locking element <NUM> is blocked in position.

In general, the inner signal contacts <NUM> can be formed integrally from sheet metal. In order to manufacture the inner signal contacts <NUM> in a cost-efficient manner, the inner signal contacts <NUM> can be designed as stamped/bent parts.

Claim 1:
A method of assembling a connector (<NUM>) for automotive applications, comprising the steps of:
providing a cable (<NUM>) having at least one inner conductor (<NUM>);
connecting at least one elongated inner signal contact (<NUM>) of the connector (<NUM>) to a stripped end (22c) of the at least one inner conductor (<NUM>);
surrounding the at least one elongated inner signal contact (<NUM>) by an insulating element (<NUM>);
placing a first shielding part (<NUM>) of the connector (<NUM>) around a first portion of the insulating element (<NUM>) from a first radial direction;
placing a second shielding part (<NUM>) of the connector (<NUM>) around a second portion of the insulating element (<NUM>) from a second radial direction generally opposite to the first radial direction; and
joining the first and second shielding parts (<NUM>, <NUM>) to form a shielding contact (<NUM>) of the connector (<NUM>) surrounding the insulating element (<NUM>),
characterized in that
the at least one elongated inner signal contact (<NUM>) is connected to the stripped end (22c) of the at least one inner conductor (<NUM>) by welding and
in that at least one of the first and second shielding part (<NUM>, <NUM>) is molded over by an electrically insulating material, wherein edges (<NUM>) of the insulating material are formed on an outer side of the at least one of the first and second shielding parts (<NUM>, <NUM>) for locking the connector in a connector housing (<NUM>) and/or by a TPA (<NUM>).