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

In such high-speed applications, every tenth of a millimeter of the interconnection channel and of the signal connectors should be within a certain data transmission (differential) impedance bandwidth (typical <NUM> +/- <NUM>Ω) and should be matched to preceding and succeeding sections. To this end, in each of these sections, metal portions of an inner contact or signal contact and an outer contact or shielding, insulating material of an insulating element and any air gaps must be balanced in size and position with respect to each other. However, there is also a need for these components to meet other non-signal-integrity requirements, in particular mechanical requirements. For example, it has to be ensured that a male signal contact is always correctly guided into a corresponding female signal contact. Also, it has to be ensured that conductors of a cable are correctly connected to the signal contacts of the connector. To achieve high data transmission, an optimum electrical and mechanical connection between a male signal contact and a female signal contact of the connector and a secure connection between the female signal contact and the conductor of the cable is indispensable.

A connector assembly and corresponding method to assemble said assembly according to the preamble of the independent claims is disclosed in <CIT>. Other connector assemblies are disclosed in <CIT> and <CIT>.

Accordingly, there is a need to provide a connector assembly of the H-MTD® kind that enables a more accurate connection between male and female signal contacts and a more secure connection between the female signal contacts and the conductors of the cable.

This demand is satisfied by a connector assembly according to claim <NUM> and a method for assembling the connector assembly according to claim <NUM>.

The present disclosure provides a connector assembly according to claim <NUM> and a method for assembling the connector assembly according to claim <NUM>. Embodiments can be taken from the dependent claims, the description and the drawings.

In one aspect, the present disclosure is directed at a connector assembly, wherein the connector assembly comprises at least one elongated inner signal contact and an insulating element. The at least one elongated inner signal contact defines an axial direction and has a tube-like connection portion, wherein the tube-like connection portion comprises a first welding opening. The insulating element comprises a first insulating part and a second insulating part, wherein the first insulating part defines at least one elongated cavity designed to accommodate the at least one elongated inner signal contact and the second insulating part comprises at least one second welding opening. The first welding opening and the at least one second welding opening are aligned in an assembled state of the connector assembly.

The connector assembly may be configured for high speed data transmission. In particular, the connector assembly may be a high speed cable assembly of the H-MTD® type comprising pre-assembled signal contacts (in other words: terminals) for automotive applications.

The connector assembly described herein is a female connector assembly, i.e. the inner signal contact is a female signal contact. The inner signal contact has a funnel-shaped end section allowing for pin movement, i.e. allowing insertion of a male signal contact pin.

The inner signal contact is embedded in an insulating element which may form a multi-part housing, in particular a two-part housing. More specifically, the insulating element, i.e. each of the first insulating part and the second insulating part of the insulating element may define a cavity having a first cavity portion which receives a tube-like main section of the inner signal contact, and a second cavity portion which receives a funnel-shaped end section of the inner signal contact. The first insulating part of the insulating element may define a third cavity portion which receives the tube-like connection portion of the elongated inner signal contact. Also, the second insulating part of the insulating element may define a third cavity portion which receives the tube-like connection portion of the elongated inner signal contact. The first insulating part and the second insulating part of the insulating element together may surround the at least one inner signal contact. The terms "first" and "second" are only used to differentiate the two insulating parts. There is no restriction to features concerning the first insulating part or the second insulating part, i.e. all features of the first insulating part may be also features of the second insulating part. A cross-sectional dimension of the first cavity portion, also referred to as a minimum cross-sectional dimension of the cavity, and an outer cross-sectional dimension of the tube-like main section may be substantially equal, i.e. the tube-like main section may be embedded in the first cavity portion with marginal clearance between the tube-like main section and the insulating material defining the first cavity portion.

Since the inner signal contact expands or flares in a direction away from the tube-like main section to form the funnel-shaped end section, a maximum outer cross-sectional dimension of the funnel-shaped end section is greater than the outer cross-sectional dimension of the tube-like main section. Consequently, the maximum outer cross-sectional dimension of the funnel-shaped end section is also greater than the cross-sectional dimension of the first cavity portion, i.e. the minimum cross-sectional dimension of the cavity, thereby making it generally impossible for the inner signal contact to be pushed along the length of the cavity.

It is to be understood that in order to be able to accommodate the funnel-shaped end section of the inner signal contact, the cross-sectional dimension of the second cavity portion, also referred to as a maximum cross-sectional dimension of the cavity, must at least correspond to the maximum outer cross-sectional dimension of the funnel-shaped end section and as such is also greater than the minimum cross-sectional dimension of the cavity.

The tube-like connection portion of the elongated inner signal contact may be an axial extension of the tube-like main section of the elongated inner signal contact in a direction opposite to the funnel-shaped end section of the inner signal contact. The axial direction may be defined as an axis extending from the funnel-shaped end section over the first cavity portion to the tube-like connection portion. The first welding opening of the inner signal contact may be a hole in an outer surface of the tube-like connection portion. The first welding opening may be configured to allow access to the interior of the tube-like connection portion of the inner signal contact, for example, to allow laser welding of a conductor inserted into the tube-like connection portion of the elongated inner signal contact to the inner signal contact.

The first insulating part and/or the second insulating part of the insulating element may comprise at least one second welding opening. The terms "first" and "second" are only used to differentiate the welding openings of the inner signal contact and the welding openings of the insulating parts. A second welding opening of the insulating element, i.e. of the first insulating part and/or the second insulating part, may be associated with a first welding opening of the inner signal contact. Thus, each welding opening of an inner signal contact may be associated with one welding opening of the insulating element. The second welding opening of the insulating element may also be configured as a hole in an outer surface of the insulating element, in particular in an outer surface of the first insulating part and/or the second insulating part. The second welding opening may be configured to allow access to the interior of the tube-like connection portion of the inner signal contact through the first welding opening of the inner signal contact, for example, to allow laser welding of a conductor inserted into the tube-like connection portion of the elongated inner signal contact to the inner signal contact when the first welding opening and the second welding opening are aligned. An alignment of the first welding opening and the second welding opening may be reached if a center line of the first welding opening and a center line of the second welding opening are substantially coaxial, wherein the center lines may be generally perpendicular to the axial direction. In particular, this may apply to an assembled state of the connector assembly. The assembled state of the connector assembly may describe a state in which the at least one elongated inner signal contact is fully received in the first insulating part of the insulating element, and the first insulating part and the second insulating part are pinched together such that the first insulating part and the second insulating part together completely surround the at least one inner signal contact.

According to an embodiment, the at least one elongated inner signal contact may comprise a funnel-shaped reception section at one axial end of the tube-like connection portion. The funnel-shaped reception section may be arranged at an end of the at least one elongated inner signal contact opposite from the funnel-shaped end section. The elongated inner signal contact may expand or flare in a direction away from the tube-like connection portion of the inner signal contact to form the funnel-shaped reception section such that a maximum outer cross-sectional dimension of the funnel-shaped reception section is greater than an outer cross-sectional dimension of the tube-like connection portion.

According to an embodiment, each of the first insulating part and the second insulating part may comprise at least one depression configured to receive the funnel-shaped reception section of the at least one elongated inner signal contact. The at least one depression may also be funnel-shaped, in particular, corresponding to the funnel-shaped reception section of the at least one elongated signal contact. The depression may be arranged adjacent the third cavity portion of the first insulating part and the second insulating part, respectively, as seen in the axial direction. The depression may expand or flare in a direction away from the third cavity such that a maximum outer cross-sectional dimension of the depression is greater than an outer cross-sectional dimension of the third cavity portion.

According to an embodiment, the second insulating part may have an end cap which comprises at least one funnel-shaped connection opening. The at least one funnel-shaped connection opening and the funnel-shaped reception section are aligned in an assembled state of the connector assembly. The end cap may cover the axial end of the first insulating part when the second insulating part is pinched onto the first insulating part. The funnel-shaped connection opening and the funnel-shaped reception section may be aligned in the axial direction of the inner signal contact.

According to an embodiment, the connector assembly may further comprise a first outer shielding contact having at least one third welding opening, wherein the first welding opening, the at least one second welding opening and the at least one third welding opening are aligned in an assembled state of the connector assembly. The terms "first", "second" and "third" are only used to differentiate the welding openings of the inner signal contact, the insulating parts and the first outer shielding contact. The third welding opening of the first outer shielding contact may be associated with the first welding opening of the inner signal contact and the respective second welding opening of the second insulating part. Thus, each welding opening of an inner signal contact may be associated with one welding opening of the insulating element and one welding opening of the first outer shielding contact. The third welding opening of the first outer shielding contact may be configured as a hole in an outer surface of the first outer shielding contact, in particular in an outer surface of a first connection end portion of the first outer shielding contact. The third welding opening may be configured to allow access to the interior of the tube-like connection portion of the inner signal contact through the first welding opening of the inner signal contact and the second welding opening of the second insulating part, for example, to allow laser welding of a conductor inserted into the tube-like connection portion of the elongated inner signal contact to the inner signal contact when the first welding opening, the respective second welding opening and the respective third welding opening are aligned. An alignment of the first welding opening, the respective second welding opening and the respective third welding opening may be reached if a center line of the first welding opening, a center line of the respective second welding opening and a center line of the respective third welding opening are substantially coaxial, wherein the center lines may be generally perpendicular to the axial direction. In particular, this applies to an assembled state of the connector assembly. The assembled state of the connector assembly may describe a state where the at least one elongated inner signal contact is fully received by the first insulating part of the insulating element, the first insulating part and the second insulating part are pinched together such that the first insulating part and the second insulating part completely surrounds the at least one inner signal contact, and the first outer shielding contact is fully slid onto the insulating element, i.e. onto the pinched first insulting part and the second insulating part.

According to this embodiment, the first insulating part may comprise at least one press fit spike configured to secure the insulating element to a first connection end portion of the first outer shielding contact.

Accordingly, the first outer shielding contact may comprise at least one gap at the first connection end portion configured to receive the at least one press fit spike.

According to an embodiment, the connector assembly may further comprise an alternative second outer shielding contact having at least one fourth welding opening, wherein the first welding opening, the at least one second welding opening, the at least one third welding opening and the at least one fourth welding opening are aligned in an assembled state of the connector assembly. The terms "first", "second", "third" and "fourth" are only used to differentiate the welding openings of the inner signal contact, the insulating parts, the first outer shielding contact and the second outer shielding contact. The fourth welding opening of the second outer shielding contact may be associated with the first welding opening of the inner signal contact, the respective second welding opening of the second insulating part and the respective third welding opening of the first outer shielding contact. Thus, each welding opening of an inner signal contact may be associated with one welding opening of the insulating element, one welding opening of the first outer shielding contact and one welding opening of the second outer shielding contact. The fourth welding opening of the second outer shielding contact may be configured as a hole in an outer surface of the second outer shielding contact. The fourth welding opening may be configured to allow access to an interior of the tube-like connection portion of the inner signal contact through the first welding opening of the inner signal contact, the second welding opening of the second insulating part and the third welding opening of the first outer shielding contact, for example, to allow laser welding of a conductor inserted into the tube-like connection portion of the elongated inner signal contact to the inner signal contact when the first welding opening, the respective second welding opening, the respective third welding opening and the respective fourth welding opening are aligned. An alignment of the first welding opening, the respective second welding opening, the respective third welding opening and the respective fourth welding opening may be reached if a center line of the first welding opening, a center line of the respective second welding opening, a center line of the respective third welding opening and a center line of the respective fourth welding opening are substantially coaxial, wherein the center lines may be generally perpendicular to the axial direction. In particular, this applies to the assembled state of the connector assembly. The assembled state of the connector assembly may describe a state where the at least one elongated inner signal contact is fully received by the first insulating part of the insulating element, the first insulating part and the second insulating part are pinched together such that the first insulating part and the second insulating part together completely surrounds the at least one inner signal contact, the first outer shielding contact is fully slid onto the insulating element and the second outer shielding contact is fully slid onto the first connection end portion of the first outer shielding contact.

In another aspect, the present disclosure is directed at a method for assembling a connector assembly according to any one of the previous embodiments. The method comprises placing the at least one elongated inner signal contact into the first insulating part of the insulating element such that the at least one elongated inner signal contact adopts a preliminary position. The method further comprises sliding, in the axial direction, the at least one elongated inner signal contact along the first insulating part into an end position, and pinching the second insulating part of the insulating element onto the first insulating part of the insulating element such that the first welding opening and the at least one second welding opening are aligned in an assembled state of the connector assembly.

According to an embodiment, the method may further comprise sliding a first connection end portion of a first outer shielding contact onto the insulating element. The first outer shielding contact may have at least one third welding opening, wherein the first welding opening, the at least one second welding opening and the at least one third welding opening are aligned in an assembled state of the connector assembly.

According to an embodiment, the method may further comprise inserting a cable comprising at least one conductor into a second connection end portion of the first outer shielding contact, such that the at least one conductor is inserted into the tube-like connection portion of the at least one elongated inner signal contact, and crimping the second connection end portion of the first outer shielding contact to the cable.

In this embodiment, the method may further comprise connecting the at least one conductor of the cable to the at least one inner signal contact via welding through the first welding opening, the at least one second welding opening and the at least one third welding opening.

In this embodiment, the method may further comprise sliding a second outer shielding contact onto the first connection end portion of the first outer shielding contact, and/or fixing the second outer shielding contact to the first outer shielding contact via welding, and/or securing the crimped second connection end portion of the first outer shielding contact via welding.

According to an alternative embodiment, the method may comprise sliding an alternative second outer shielding contact having at least one fourth welding opening onto the first connection end portion of the first outer shielding contact, and/or inserting a cable into a second connection end portion of the first outer shielding contact, wherein the cable may comprise at least one conductor which is inserted into the tube-like connection portion of the at least one elongated inner signal contact, and/or crimping the second connection end portion of the first outer shielding contact to the cable, and/or connecting the at least one conductor of the cable to the at least one inner signal contact via welding through the first welding opening, the at least one second welding opening, the at least one third welding opening and the at least one fourth welding opening, and/or securing the crimped second connection end portion of the first outer shielding contact via welding.

According to another aspect, the present disclosure is directed at a connector assembly which comprises at least one elongated inner signal contact having a first connection portion, wherein the first connection portion comprises a tube-like main section and a funnel-shaped end section; and an insulating element, wherein the insulating element defines at least one elongated cavity designed to accommodate the elongated inner signal contact, wherein a maximum outer cross-sectional dimension of the funnel-shaped end section is greater than a minimum cross-sectional dimension of the elongated cavity.

According to an embodiment, the funnel-shaped end section may comprise a first end section part and a second end section part, wherein the first end section part and the second end section part are separated by two air gaps. The air gaps may be diagonally arranged, i.e. the two air gaps are arranged opposite from each other. The first end section and the second end section of the funnel-shaped end section allow a spreading apart of the funnel-shaped end section to thereby make the insertion of a male signal contact pin easier. According to another embodiment, the funnel-shaped end section may be a machined end section or a stamped, rolled, or bended end section, in which a first end section part and a second end section part are separated by just one small slit.

According to an embodiment, the insulating element may comprise at least one front opening configured to receive the funnel-shaped end section, and two chamfers protruding into the air gaps such that the first end section part, the second end section part and the two chamfers define an inlet. In other words, the chamfers may radially protrude into the front opening. The two chamfers may be arranged diagonally to each other.

The front opening of the insulating element may be configured to receive a male signal contact, and the inlet serves to lead the male signal contact into the female inner signal contact of the connector assembly. The inlet may provide an at least approximately <NUM>° lead-in cone to guide the male signal contact into the tube-like main section of the female inner signal contact. Thus, an incorrect connection of the signal contacts can be prevented which may occur by inserting the male signal contact past the inner signal contact. Furthermore, damage to at least one of the male signal contact, the inner signal contact and the insulating element may be avoided.

According to an embodiment, the funnel-shaped end section comprises a first end section part and a second end section part, wherein the first end section part and the second end section part are separated by two air gaps, and wherein the insulating element comprises at least one rib engaging one of the air gaps and thereby widening the funnel-shaped end section. By widening the funnel-shaped end section the size of the inlet may be maximized. The two air gaps may be arranged diagonally to each other.

According to an embodiment, the insulating element and the at least one elongated inner signal contact may comprise at least one protrusion and at least one recess, respectively, wherein the protrusion and the recess are configured to cooperate in order to at least reduce or even prevent a rotation and/or an axial movement of the at least one elongated inner signal contact relative to the insulating element. The at least one protrusion may be a blocking element that provides a forward stop and/or a backward stop for the at least one elongated inner signal contact in the insulating element. A precise rotational control and limitation of movement of the inner signal contact as well as a precise rigid back and forward stop of the inner signal contact may thus be achieved.

According to an embodiment, the insulating element may comprise a control element and the at least one elongated inner signal contact may comprise a hole receiving the control element when the connector assembly is correctly assembled. The control element may be visible in the hole of the at least one elongated inner signal contact when the at least one elongated inner signal contact reaches its correct end-position during assembling. Thus, easy visual confirmation of a correct assembly of the at least one elongated inner signal contact in the insulating element is possible.

According to an embodiment, the insulating element may comprise at least one clamping element configured to secure a wire to which the at least one elongated inner signal contact is connected.

According to an embodiment, the at least one elongated inner signal contact may comprise a termination element configured to receive a wire and the insulating element may comprise at least one retaining element configured to secure the termination element and/or the wire in the insulating element. The termination element may comprise a pair of crimping wings or any other suitable termination means.

According to another embodiment, the insulating element may comprise a first insulating part and a second insulating part, wherein the first insulating part and the second insulating part together surround the at least one inner signal contact.

The terms "first" and "second" are only used to differentiate the two insulation parts. There is no restriction to features concerning the first insulating part or the second insulating part, i.e. all features of the first insulating part may be also features of the second insulating part.

According to an embodiment, one of the first insulating part and the second insulating part may be configured to be radially mounted in respect of the at least one elongated inner signal contact and the respective other one of the first insulating part and the second insulating part is configured to be axially slid onto the at least one elongated inner signal contact.

According to an embodiment, the at least one elongated inner signal contact may be pinched into the first insulating part or the second insulating part.

According to an embodiment, the first insulating part or the second insulating part may comprise a press fit element configured to secure the first insulating part to the second insulating part.

According to an embodiment, the first insulating part or the second insulating part may comprise at least one locking element configured to snap fit the first insulating part and the second insulating part together and thereby secure the first insulating part to the second insulating part. The locking element may provide a passive lock and/or an active lock.

According to an embodiment, the first insulating part or the second insulating part may comprise a pin and the respective other one of the first insulating part and the second insulating part comprises a slot, wherein the slot is configured to receive the pin and the pin is deformed and secured in the slot to thereby secure the first insulating part to the second insulating part.

According to an embodiment, the first insulating part or the second insulating part may comprise a groove and the respective other one of the first insulating part and the second insulating part may comprise a tongue received in the groove.

According to an embodiment, the first insulating part or the second insulating part may comprise a locking cavity and the respective other one of the first insulating part and the second insulating part may comprise a locking protrusion received in the locking cavity.

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 an 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 male connector, and a second connection portion <NUM> for connecting the signal contacts <NUM> to respective conductors <NUM> of a cable <NUM>. The conductors <NUM> may be strands. Furthermore, the conductors <NUM> may be embedded in a wire insulation <NUM>. The second connection portion <NUM> may include a termination element <NUM> comprising, for example, two crimping wings (shown in <FIG>) or may have a welding portion having a welding opening <NUM> (shown in <FIG>). The welding opening <NUM> may be used to connect the signal contacts <NUM> to respective conductors <NUM> of the cable <NUM> via laser welding or ultrasonic welding. Alternatively, resistance welding can be used to connect the signal contacts <NUM> to respective conductors <NUM> of the cable <NUM>.

The inner signal contacts <NUM> are arranged in an insulating element <NUM> which may form a di-electric housing. In the embodiment shown in <FIG>, the insulating element <NUM> comprises two separate insulating parts, a first insulating part 28a and a second insulating part 28b, which together enclose the inner signal contacts <NUM>. The first insulating part 28a and the second insulating part 28b may be attached to each other, for example, by a click-on connection, i.e. by a snap fit engagement. It is to be understood that the first insulating part 28a and the second insulating part 28b may be attached to each other by other suitable connections, as will be described further below. Furthermore, it is to be understood that the insulating element <NUM> may also be a one-part insulating element <NUM>, for example, produced by injection molding, i.e. by overmolding the inner signal contacts <NUM>. In such an insulating element <NUM>, undesirable air pockets may be minimized.

The first insulating part 28a fulfills the task of locking the signal contacts <NUM> in the axial direction <NUM> so that the inner signal contacts <NUM> maintain their axial position when the connector <NUM> is connected to a mating connector. It is to be understood that, additionally or alternatively, the second insulating part 28b may fulfill the task of locking the signal contacts <NUM> in the axial direction <NUM>.

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 connector <NUM> comprises multiple shielding contacts <NUM>. At a proximal end <NUM> of the connector <NUM>, the first shielding part <NUM> forms a cover <NUM>. 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 connector <NUM> comprises an inner crimp ferrule <NUM> which is placed around the cable <NUM>.

The inner signal contacts <NUM> and the insulating element <NUM> together form a connector assembly <NUM> according to an embodiment of the present disclosure, as shown in <FIG> shows an exploded view of the connector assembly <NUM>.

<FIG> depict a perspective view of the inner signal contacts <NUM> according to various embodiments. The 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 contact <NUM> to a respective conductor <NUM> of a cable <NUM> (<FIG>). The first connection portion <NUM> has a tube-like main section <NUM> defining a first centre axis <NUM> and a funnel-shaped end section <NUM>, wherein the tube-like main section <NUM> may have a round, in particular a generally circular or oval, or a polygonal cross-section. The second connection portion <NUM> defines a second centre axis <NUM> where a centre axis of the cable <NUM> is placed at. A distance A between the centre axes <NUM> of the first connection portions <NUM> may be equal or larger than a distance B between the centre axes <NUM> of the second connection portions <NUM>. Alternatively, a distance A between the centre axes <NUM> of the first connection portions <NUM> may be smaller than a distance B between the centre axes <NUM> of the second connection portions <NUM>. In other words, the inner signal contacts <NUM> may be formed so that a pitch translation may be generated. Each of the inner signal contacts <NUM> may be formed so that the first centre axis <NUM> is spaced apart in parallel from the second centre axis <NUM>.

In another embodiment, shown in <FIG>, 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 first connection portions <NUM>. The hooks <NUM> help to axially fix the inner signal contacts <NUM> in the insulating element <NUM>.

The second connection portions <NUM> of the inner signal contacts <NUM> may comprise welding openings <NUM> (<FIG>) that are arranged to allow, for example, a laser beam to weld a conductor <NUM> to the inner signal contacts <NUM>. Alternatively, termination elements <NUM> can be formed at the second connection portions <NUM> so that the inner signal contacts <NUM> can be attached onto the wires insulating <NUM> of the cable <NUM> (<FIG>).

The inner signal contacts <NUM> may comprise signal contact portions <NUM>. In one embodiment, the signal contact portions <NUM> may have an oval cross-section, as shown in <FIG>. In another embodiment the signal contact portions <NUM> may have a U-shaped cross-section, as shown in <FIG>. In yet another embodiment, the signal contact portions <NUM> may have a circular cross-section, as shown in <FIG>. It is to be understood, that the shape of the signal contact portions <NUM> is not limited to the shapes shown in <FIG>. Rather, the signal contact portions <NUM> may be of any suitable shape. The signal portions <NUM> may be configured to at least reduce or even prevent a rotation and/or an axial movement of the at least one elongated inner signal contact <NUM> relative to the insulating element <NUM>. The signal portions <NUM> may be defined as blocking elements that provide a forward stop and/or a backward stop for the at least one elongated inner signal contact <NUM> in the insulating element <NUM>. A precise rotational control and limitation of movement of the inner signal contact <NUM> as well as a precise rigid back and forward stop of the inner signal contact <NUM> may thus be achieved. The signal portions <NUM> may also be configured to receive a wire insulation <NUM>.

<FIG> show cross-sectional views of a connector assembly <NUM> in a partly assembled state (<FIG>) and in a fully assembled state (<FIG>). The connector assembly <NUM> comprises at least one elongated inner signal contact <NUM>, in the present embodiment two inner signal contacts <NUM>. Each inner signal contact <NUM> comprises a first connection portion <NUM> having a tube-like main section <NUM> and a funnel-shaped end section <NUM>. The tube-like main section <NUM> may have a round, in particular a generally circular or oval, or a polygonal cross-section. The funnel-shaped end section <NUM> expands from one end of the tube-like main section <NUM> such that a maximum outer cross-sectional dimension C of the funnel-shaped end section <NUM> is greater than a maximum outer cross-sectional dimension of the tube-like main section <NUM>.

The at least one elongated inner signal contact <NUM> is accommodated in an elongated cavity <NUM> of the insulating element <NUM>. A first part of the cavity <NUM> is designed to generally form fittingly receive the tube-like main section <NUM>, i.e. a cross-sectional dimension of the first part of the cavity <NUM> is generally equal to the outer cross-sectional dimension of the tube-like main section <NUM>, and a second part of the cavity <NUM> makes room for the funnel-shaped end section <NUM>. In other words, a cross-sectional dimension D of the first part of the cavity <NUM>, also referred to as a minimum cross-sectional dimension D of the cavity <NUM>, corresponds to the outer cross-sectional dimension of the tube-like main section <NUM>, whereas a cross-sectional dimension of the second part of the cavity <NUM>, also referred to as a maximum cross-sectional dimension of the cavity <NUM>, is at least equal to or greater than the maximum outer cross-sectional dimension C of the funnel-shaped end section <NUM>. Since the maximum outer cross-sectional dimension C of the funnel-shaped end section <NUM> is greater than the maximum outer cross-sectional dimension of the tube-like main section <NUM>, the maximum outer cross-sectional dimension C of the flaring funnel-shaped end section <NUM> is also greater than the cross-sectional dimension D of the first part of the cavity <NUM>, i.e. the minimum cross-sectional dimension D of the cavity <NUM>. It is to be understood that the dimensions described herein may be diameters if the tube-like main section <NUM> and the cavity <NUM> are of circular cross-section.

<FIG> show a perspective view and a cross-sectional view, respectively, of the funnel-shaped end section <NUM> of the inner contact <NUM>. The funnel-shaped end section <NUM> comprises a first end section part <NUM> and a second end section part <NUM>. The first end section part <NUM> and the second end section part <NUM> are separated by two air gaps <NUM>, i.e. there is a clearance between the first end section part <NUM> and the second end section part <NUM>. The first end section part <NUM> and the second end section part <NUM> may be diagonally arranged, i.e. arranged opposite from each other. Accordingly, the two air gaps <NUM> may be diagonally arranged, i.e. arranged opposite from each other.

As shown in <FIG>, each cavity <NUM> ends in a front opening <NUM> of the insulating element <NUM>, which allows a mating contact to be connected to the inner contact <NUM> arranged in the cavity <NUM>. Each front opening <NUM> is configured to receive the funnel-shaped end section <NUM> of the inner signal contact <NUM>. Two, for example, diagonally arranged chamfers <NUM> protrude into the front opening <NUM> and, more specifically, into the air gaps <NUM> of the funnel-shaped end section <NUM> received in the front opening <NUM>.

When the funnel-shaped end section <NUM> is received in the front opening <NUM>, the first end section part <NUM>, the second end section part <NUM> and the two chamfers <NUM> together define an inlet <NUM> configured to correctly guide a matching male signal contact (not shown) into the female inner signal contact <NUM>. The inlet <NUM> may form a <NUM>-degree lead-in cone, in particular having an at least substantially closed perimeter, to guide the male signal contact into the inner signal contact <NUM>. Depending on the geometrical definition of the end section parts <NUM>, <NUM> and the corresponding chamfers <NUM>, the inlet may be of round, in particular circular or oval, or of polygonal cross-section.

<FIG> show a part of the insulating element <NUM> having inner signal contacts <NUM> in a partly assembled state of the connector assembly <NUM>. The insulating element <NUM> comprises at least one rib <NUM> in each cavity <NUM>, wherein the rib <NUM> may be an extension of one of the chamfers <NUM> in a direction of the first centre axis <NUM> defined by the respective inner signal contact <NUM>. The rib <NUM> engages one of the air gaps <NUM> when the funnel-shaped end section <NUM> of the inner signal contact <NUM> is inserted into the front opening <NUM> and thereby widens the funnel-shaped end section <NUM>. In a not fully assembled state (<FIG>), the funnel-shaped end section <NUM> of the inner signal contact <NUM> is not in contact with the rib <NUM> and, thus, in a relaxed state.

<FIG> shows a perspective view and <FIG> shows a cross-sectional view of the part of the insulating element <NUM> having inner signal contacts <NUM> in a fully assembled state of the connector assembly <NUM>. When the inner signal contacts <NUM> are inserted into the insulating element <NUM>, the funnel-shaped end section <NUM>, in particular the first end section part <NUM> and the second end section part <NUM> are pushed apart by the rib <NUM> as shown in <FIG>.

<FIG> show cross-sectional top views and a cross-sectional side views of further embodiments of the connector assembly <NUM> in which the insulating element <NUM> comprises at least one protrusion <NUM> and at least one recess <NUM> for each inner signal contact <NUM>. The at least one respective inner signal contact <NUM> also comprises at least one protrusion <NUM> and at least one recess <NUM>, respectively. The at least one protrusion <NUM> of the insulating element <NUM> engages with the at least one recess <NUM> of the inner signal contact <NUM>, and vice versa. In other words, the protrusions <NUM>, <NUM> and the recesses <NUM>, <NUM> are configured to cooperate in order to substantially prevent a rotation and/or an axial movement of the inner signal contact <NUM> relative to the insulating element <NUM>. More specifically, the rotation and/or the axial movement of the inner signal contact <NUM> relative to the insulating element <NUM> is reduced, or minimized, or limited to some degree, such that only an insignificant amount of rotation and axial movement of the inner signal contact <NUM> relative to the insulating element <NUM> may occur.

The insulating element <NUM> may comprise two protrusions <NUM> for each inner signal contact <NUM>, wherein one protrusion <NUM> of the insulating element <NUM> is arranged in front of the protrusion <NUM> of the inner signal contact <NUM> and one protrusion <NUM> of the insulating element <NUM> is arranged behind the protrusion <NUM> of the inner signal contact <NUM>, as shown in <FIG>. The protrusion <NUM> of the insulating element <NUM> arranged in front of the protrusion <NUM> of the inner signal contact <NUM> may act as a forward stop or a backward stop and the protrusion <NUM> of the insulating element <NUM> arranged behind the protrusion <NUM> of the inner signal contact <NUM> may act as a backward stop. A forward stop may reduce or even prevent an axial movement of the at least one elongated inner signal contact <NUM> relative to the insulating element <NUM> in a forward direction, i.e. in a direction towards the funnel-shaped end section <NUM> of the inner signal contact <NUM>. A backward stop may reduce or even prevent an axial movement of the at least one elongated inner signal contact <NUM> relative to the insulating element <NUM> in a backward direction, i.e. in a direction towards the second connection portion <NUM> of the inner signal contact <NUM>.

<FIG> shows a perspective view of a part of an insulating element <NUM> having two inner signal contacts <NUM> wherein each inner signal contact <NUM> comprises a hole <NUM> defined to receive a corresponding control element <NUM> of the insulating element <NUM>. The control elements <NUM> are arranged such that they engage with the holes <NUM> when the connector assembly <NUM> is correctly assembled, i.e. when the inner signal contacts <NUM> are correctly embedded in the insulating element <NUM>. <FIG> show the control elements <NUM> inserted into the holes <NUM> of U-shaped signal contact portions <NUM> of the inner signal contacts <NUM>. It is to be understood that the holes <NUM> and, thus, the control elements <NUM> may also be arranged at other parts of the inner signal contacts <NUM>. The control elements <NUM> are visible in the holes <NUM> of the inner signal contacts <NUM> when the inner signal contacts <NUM> reach an end-position during the assembling of the connector assembly <NUM>. Thus, a visual control of the end-position of the inner signal contacts <NUM> is possible when the inner signal contacts <NUM> are mounted in the insulating element <NUM>.

<FIG> show an insulating element <NUM> according to a further embodiment. The insulating element <NUM> comprises at least one clamping element <NUM> in each cavity <NUM>, which is configured to secure the wire insulation <NUM> of a cable <NUM> (not shown) and/or a conductor <NUM> to which the respective inner signal contact <NUM> is connected. To secure the wire insulation <NUM> or the conductor <NUM> in the insulating element <NUM>, a gap defined by two opposing clamping elements <NUM> is less than a main diameter of the wire insulation <NUM> or the conductor <NUM>. Thus, the wire insulation <NUM> or the conductor <NUM> is clamped in the insulating element <NUM> when the wire insulation <NUM> or the conductor <NUM> is inserted into the gap.

<FIG> shows a perspective view of a part of the insulating element <NUM> having two inner signal contacts <NUM> according to a further embodiment. The inner signal contacts <NUM> each comprise a termination element <NUM>, for example, a pair of crimping wings, arranged at the second connection portion <NUM>, wherein the termination element <NUM> may be configured to secure a wire insulation <NUM> or a conductor <NUM>, e.g. a conductor, in the inner signal contact <NUM>. The insulating element <NUM> comprises at least one retaining element <NUM> for each inner signal contact <NUM>, which is configured to secure at least one of the respective termination element <NUM>, the respective wire insulation <NUM>, the conductor <NUM> and a respective signal contact portion <NUM> in the insulating element <NUM>. Each retaining element <NUM> may be designed as a snap arm, wherein two opposing retaining elements <NUM> may form a cavity that is configured to hold or secure the termination element <NUM> or the wire insulation <NUM>.

<FIG> shows another embodiment of a part of an insulating element <NUM> in which the retaining element <NUM> is designed as a bracket that encloses at least one of the termination element <NUM>, the wire insulation <NUM>, the conductor <NUM> and the signal contact <NUM>. The shape of the bracket may be adapted to the contour of the received element. For example, the bracket may define circular cavities to receive the signal contact portions <NUM> of the inner signal contacts <NUM>.

<FIG> shows a cross-sectional view of a further embodiment of a first insulating part 28a having two inner signal contacts <NUM> in a partly assembled state. The first insulating part 28a may be radially mounted to the inner signal contacts <NUM>. As shown in <FIG>, the inner signal contacts <NUM>, in particular the signal contact portions <NUM>, are pinched into the first insulating part 28a in a fully assembled state of the connector assembly <NUM>. To this end, the signal contact portions <NUM> may have a greater cross-sectional dimension than respective cavities <NUM> of the first insulating part 28a (<FIG>). By pressing the signal contact portions <NUM> into the cavities <NUM>, the cross-sectional dimension of the signal contact portions <NUM> is reduced to a cross-sectional dimension of the cavity <NUM> as shown in <FIG>. Furthermore, due to the reduction of the cross-sectional dimension of the signal contact portions <NUM>, the wire insulations <NUM> or the conductors <NUM> attached to the inner signal contacts <NUM> are secured in the signal contact portions <NUM>. The second insulating part 28b of the insulating element <NUM> may then be axially slid onto the inner signal contacts <NUM> in a direction of the first centre axis <NUM> defined by the inner signal contacts <NUM> such that the inner signal contacts <NUM> are fully enclosed by the first insulating part 28a and the second insulating part 28b. A detailed description of an assembly process will be described further below.

Alternatively, according to another embodiment, the inner signal contacts <NUM> may be inserted into the second insulating part 28b as shown in <FIG>. More specifically, <FIG> shows the inner signal contacts <NUM> in their final position in the second insulation part 28b, but not yet in their fully assembled state since the first insulating part 28a is still to be mounted. Thus, one elongated inner signal contact <NUM> is pinched into the first insulating part 28a by radially mounting the first insulating part 28a in respect of the at least one elongated inner signal contact <NUM> and the second insulating part 28b, as shown in <FIG>. The cross-sectional dimension of the signal contact <NUM> is reduced to a cross-sectional dimension of the cavity <NUM> by pressing the first insulating part 28a onto the signal contact <NUM>. Thus, the inner signal contact <NUM>, in particular the signal contact <NUM>, is pinched into the first insulating part 28a as shown in <FIG>in a fully assembled state of the connector assembly <NUM>.

<FIG> and <FIG> show two embodiments of a first insulating part 28a having two press fit elements <NUM>. The press fit elements <NUM> may be formed as cuboidal elements having protrusions <NUM> that protrude over the surfaces of the cuboidal elements, as shown in <FIG> and <FIG>. Respective elements of the second insulating part 28b may be formed as cuboidal recesses <NUM> configured to receive the press fit elements <NUM> of the first insulating part 28a. A cross-sectional dimension of the cuboidal recesses <NUM> may be substantially the same as a cross-sectional dimension of the corresponding press fit elements <NUM> (the protrusions <NUM> not considered). When the first insulating part 28a and the second insulating part 28b are radially mounted to the inner signal contacts <NUM>, the press fit elements <NUM> are inserted into the corresponding cuboidal recesses <NUM>. The press fit elements <NUM> are secured in the recesses <NUM> by means of the protrusions <NUM>. More specifically, the press fit elements <NUM> have to be pressed into the recesses <NUM> since the protrusions <NUM> lead to a cross-sectional dimension of the press fit elements <NUM> greater than that of the recesses <NUM>. Depending on the arrangement of the protrusions <NUM>, either radial forces <NUM> (<FIG>) or axial forces <NUM> (<FIG>) act between the first insulating part 28a, in particular the press fit elements <NUM>, and the second insulating part 28b.

According to other embodiments shown in <FIG> and <FIG>, a first insulating part 28a has at least one locking element <NUM>. The locking element <NUM> may be formed as a cuboidal element having a mushroom head <NUM> (<FIG>) or having a Y-shaped or forked head <NUM> (<FIG>). The second insulating part 28b comprises a matching substantially cuboidal locking recess <NUM> configured to receive the locking element <NUM> of the first insulating part 28a. The locking recess <NUM> may comprise a first recess part 80a and a second recess part 80b, as shown in <FIG> and <FIG>. A cross-sectional dimension of the first recess part 80a may be substantially the same as a cross-sectional dimension of the cuboidal locking element <NUM>, i.e. the cuboidal locking element <NUM> fits into the first recess part 80a. A maximum outer cross-sectional dimension of the mushroom head <NUM> or the fork head <NUM> is greater than the cross-sectional dimension of the first recess part 80a. Thus, the locking element <NUM> has to be pressed through the first recess part 80a of the locking recess <NUM> until the mushroom head <NUM> or the fork head <NUM> reaches into the second recess part 80b. A cross-sectional dimension of the second recess part 80b of the locking recess <NUM> is greater than the maximum outer cross-sectional dimension of the mushroom head <NUM> or the forked head <NUM> and, thus, also greater than the first recess part 80a such that the first recess part 80a and the second recess part 80b of the locking recess <NUM> define a shoulder <NUM> at their transition (<FIG> and <FIG>). When the locking element <NUM> is fully inserted into the locking recess <NUM>, the mushroom head <NUM> or the forked head <NUM> sits on the shoulder <NUM> and thereby secures the first insulating part 28a to the second insulating part 28b (<FIG> and <FIG>).

<FIG> shows an embodiment of a first insulating part 28a and a second insulating part 28b having a locking pin <NUM> and a locking slot <NUM>, respectively, in a partly assembled state of the connector assembly <NUM>. The locking slot <NUM> is configured to receive the locking pin <NUM>. The locking slot <NUM> comprises a first slot part 86a and a second slot part 86b. A cross-sectional dimension of the first slot part 86a of the locking slot <NUM> may be substantially the same as a cross-sectional dimension of the locking pin <NUM>, i.e. the locking pin <NUM> fits into the first slot part 86a of the locking slot <NUM> (<FIG>). A cross-sectional dimension of the second slot part 86b is greater than the cross-sectional dimension of the locking pin <NUM> such that the first slot part 86a and the second slot part 86b define a shoulder <NUM> (<FIG>). The locking slot <NUM> may be similar to the locking recess <NUM> described above. When the locking pin <NUM> is fully inserted into the locking slot <NUM> the locking pin <NUM> may be deformed by means of a punch tool <NUM>. The punch tool <NUM> presses on to a free end of the locking pin <NUM> such as to deform the free end of the locking pin <NUM> into a mushroom head that sits on the shoulder <NUM>, thereby securing the first insulating part 28a to the second insulating part 28b (<FIG>). The locking pin <NUM> may be deformable in a cold or a hot state, i.e. the locking pin <NUM> is deformable by means of the punch tool <NUM> with or without preheating the locking pin <NUM> or the punch tool <NUM>.

<FIG> shows a first insulating part 28a having two tongues <NUM>. The second insulating part 28b comprises corresponding grooves <NUM> in which the tongues <NUM> can be received. The first insulating part 28a is secured to the second insulating part 28b by inserting the tongues <NUM> into their associated grooves <NUM> and axially sliding the first insulating part 28a relative to the second insulating part 28b in a direction of the centre axes <NUM> defined by the inner signal contacts <NUM>. <FIG> show a cross-sectional view of one of the tongues <NUM> inserted into its associated groove <NUM>. A maximum outer dimension of the tongue <NUM> may be substantially the same as a maximum inner dimension of the groove <NUM>, i.e. the tongue <NUM> may fit into the groove <NUM>. In an alternative embodiment shown in <FIG>, the maximum outer dimension of the tongue <NUM> may be somewhat greater than the maximum inner dimension of the groove <NUM>. Therefore, the tongue <NUM> has to be forced into the groove <NUM> and is somewhat deformed when fully inserted into the groove <NUM>.

<FIG> and <FIG> show two embodiments of an insulating element <NUM> in which a first insulating part 28a comprises a locking cavity <NUM> and a second insulating part 28b comprises a locking protrusion <NUM> to be received in the locking cavity <NUM>. The locking protrusion <NUM> extends into the locking cavity <NUM> when the connector assembly <NUM> is correctly assembled.

<FIG> depict a process of assembling a connector assembly <NUM> having an insulating element <NUM> as described in connection with <FIG>. First, conductors <NUM> of a cable <NUM> are connected to the inner signal contacts <NUM> by attaching the wire insulations <NUM> to the inner signal contacts <NUM> by means of a termination element <NUM>, for example, crimping wings. A first insulating part 28a is then radially mounted to the inner signal contacts <NUM> such that the inner signal contacts <NUM> are embedded in cavities <NUM> of the first insulating part 28a. Once the inner signal contacts <NUM> are arranged in the cavities <NUM>, the first insulation part 28a is axially slid into position along the inner signal contacts <NUM> in a direction of the centre axes <NUM> defined by the inner signal contacts <NUM> (<FIG>). By sliding the first insulating part 28a in the direction of the centre axes <NUM>, funnel-shaped end sections <NUM> of the inner signal contacts <NUM> are optionally widened by means of ribs <NUM>, if ribs <NUM> are arranged in a front opening <NUM> of the first insulation part 28a, as described above. Subsequently, a second insulating part 28b is radially mounted to the inner signal contacts <NUM> and secured to the first insulating part 28a (<FIG>) as described above.

<FIG> depict an alternative process of assembling a connector assembly <NUM> as described herein. First, conductors <NUM> of a cable <NUM> are connected to the inner signal contacts <NUM> by attaching the wire insulations <NUM> to the inner signal contacts <NUM> by means of a termination element <NUM>, for example crimping wings. A second insulating part 28b is then radially mounted to the inner signal contacts <NUM> such that the inner signal contacts <NUM> are embedded in cavities <NUM> of the second insulating part 28b (<FIG>). Once the inner signal contacts <NUM> are secured in the second insulating part 28b as described above, a first insulating part 28a is mounted to the second insulating part 28b, as shown in <FIG>. The first insulation part 28a is axially slid onto the inner signal contacts <NUM> in a direction of the centre axes <NUM> defined by the inner signal contacts <NUM>. By sliding the first insulating part 28a in the direction of the centre axes <NUM> of the inner signal contacts <NUM>, funnel-shaped end sections <NUM> of the inner signal contacts <NUM> enter front openings <NUM> of the first insulating part 28a and are optionally widened by means of ribs <NUM>, if ribs <NUM> are arranged in the front openings <NUM>, as described above. The first insulating part 28a is secured to the second insulation part 28b by means as described above, for example, by means of tongues <NUM> and grooves <NUM>.

<FIG> depict another process of assembling a connector assembly <NUM>, in particular for inner signal contacts <NUM> having welding openings <NUM> to connect the inner signal contacts <NUM> to conductors <NUM> of a cable <NUM> via welding, e.g. laser, ultrasonic or resistance welding. <FIG> shows a step of inserting inner signal contacts <NUM> into a first insulating part 28a. The inner signal contacts <NUM> are axially slid into cavities <NUM> of the first insulating part 28a in a direction of the centre axes <NUM> defined by the inner signal contacts <NUM>. Thus, the inner signal contacts <NUM> may be secured in the first insulating part 28a by features as described above, for example, by means of hooks <NUM>. Once the inner signal contacts <NUM> are secured in the first insulating part 28b, a step of attaching conductors <NUM> of a cable <NUM> to the inner contacts <NUM> follows, as shown in <FIG>. The conductors <NUM> are connected to the inner signal contacts <NUM> via laser welding or ultrasonic welding or resistance welding in the welding openings <NUM>. Subsequently, a second insulating part 28b is attached to the first insulating part 28a (<FIG>). More specifically, the second insulating part 28b is radially mounted to the inner signal contacts <NUM> and the first insulating part 28a. Therein, the second insulation part 28b is secured to the first insulating part 28a by means as described above.

<FIG> depicts an exploded view of a cable assembly according to an embodiment of the present disclosure. The cable assembly includes two elongated inner signal contacts <NUM> arranged generally parallel to each other along an axial direction <NUM>. The inner signal contacts <NUM> have a tube-like connection portion <NUM> for connecting the inner signal contacts <NUM> to respective conductors <NUM> of a cable <NUM>. In the present example, the conductors <NUM> are formed from strands, although other types of conductors <NUM> are generally conceivable. The conductors <NUM> are embedded in a wire insulation <NUM>. The tube-like connection portion <NUM> of the inner signal contact <NUM> includes a first welding opening <NUM>. The first welding opening <NUM> may be used to connect the inner signal contacts <NUM> to respective conductors <NUM> of the cable <NUM> via laser welding or ultrasonic welding. Alternatively, resistance welding can be used to connect the signal contacts <NUM> to respective conductors <NUM> of the cable <NUM>.

The inner signal contacts <NUM> are arranged in an insulating element <NUM> which may form a di-electric housing. The insulating element <NUM> includes two separate insulating parts, a first insulating part 228a and a second insulating part 228b, which together completely surround the inner signal contacts <NUM>. The first insulating part 228a and the second insulating part 228b may be attached to each other, for example, by a click-on connection, i.e. by a snap fit engagement. It is to be understood that the first insulating part 228a and the second insulating part 228b may be attached to each other by other suitable connections, as described herein.

In an assembled state of a connector assembly <NUM>, a portion of the insulating element <NUM> may be arranged in a first connection end portion <NUM> of a first outer shielding contact <NUM>. The cable <NUM> may be arranged in a second connection end portion <NUM> of the first outer shielding contact <NUM>. The second connection end portion <NUM> of the first outer shielding contact <NUM> is configured to connect the first outer shielding contact <NUM> to the cable <NUM> mechanically and electrically. The first outer shielding contact <NUM> surrounds the inner signal contacts <NUM> and the insulating element <NUM> to provide a shield against interfering signals. However, the first outer shielding contact <NUM> may also be used as an electrical conductor to transport electric power. The first connection end portion <NUM> of the first outer shielding contact <NUM> may be received by a second outer shielding contact <NUM> including multiple shielding contacts <NUM>. Furthermore, the cable assembly may include an inner crimp ferrule <NUM> which is placed around the cable <NUM>.

<FIG> depicts an exploded view of a part of the connector assembly <NUM>. The inner signal contacts <NUM> each include a funnel-shaped reception section <NUM> at one axial end of the tube-like connection portion <NUM>. The funnel-shaped reception section <NUM> is received by a depression <NUM> arranged at one end of the first insulating part 228a and the second insulating part 228b (not shown in <FIG>), respectively. The funnel-shaped reception section <NUM> may be an interference feature that is shaped complimentary to the depression <NUM> in order to hold the inner signal contacts <NUM> in position. Each of the elongated inner signal contacts <NUM> is accommodated in an elongated cavity <NUM> of the first insulating element 228a. A first part <NUM> of the cavity <NUM> is designed to generally form fittingly receive a tube-like main section <NUM> of the inner signal contact <NUM>, i.e. a cross-sectional dimension of the first part <NUM> of the cavity <NUM> is generally equal to the outer cross-sectional dimension of the tube-like main section <NUM> of the inner signal contact <NUM>, and a second part <NUM> of the cavity <NUM> makes room for the funnel-shaped end section <NUM> of the inner signal contact <NUM>. In other words, a cross-sectional dimension D (see <FIG>) of the first part <NUM> of the cavity <NUM>, also referred to as a minimum cross-sectional dimension D of the cavity <NUM>, corresponds to the outer cross-sectional dimension of the tube-like main section <NUM>, whereas a cross-sectional dimension of the second part <NUM> of the cavity <NUM>, also referred to as a maximum cross-sectional dimension of the cavity <NUM>, is at least equal to or greater than the maximum outer cross-sectional dimension C of the funnel-shaped end section <NUM> of the inner signal contact <NUM>. Since the maximum outer cross-sectional dimension C of the funnel-shaped end section <NUM> is greater than the maximum outer cross-sectional dimension of the tube-like main section <NUM>, the maximum outer cross-sectional dimension C of the flaring funnel-shaped end section <NUM> is also greater than the cross-sectional dimension D of the first part <NUM> of the cavity <NUM>, i.e. the minimum cross-sectional dimension D of the cavity <NUM>. It is to be understood that the dimensions described herein may be diameters if the tube-like main section <NUM> and the cavity <NUM> are of circular cross-section (see <FIG>).

The first insulating part 228a may fulfill the task of locking the signal contacts <NUM> in the axial direction <NUM> so that the inner signal contacts <NUM> maintain their axial position when the connector assembly <NUM> is connected to a mating connector. It is to be understood that, additionally or alternatively, the second insulating part 228b may also fulfill the task of locking the signal contacts <NUM> in the axial direction <NUM>.

<FIG> depict a process of assembling the connector assembly <NUM> of <FIG>. <FIG> shows a step of placing inner signal contacts <NUM> into cavities <NUM> of a first insulating part 228a of the insulating element <NUM>. More specifically, the inner signal contacts <NUM> are placed, for example in a radial direction, into the first insulating part 228a so as to adopt a preliminary position in the cavities <NUM>. The tube-like main section <NUM> of each inner signal contact <NUM> is form fittingly received in a first part <NUM> of the cavity <NUM>. The funnel-shaped end section <NUM> of each inner signal contact <NUM> is received in a second part <NUM> of the cavity <NUM>. In this preliminary position of the inner signal contacts <NUM> in the first insulating element 228a, the funnel-shaped reception section <NUM> at the axial end of the tube-like connection portion <NUM> opposite from the funnel-shaped end section <NUM> of each inner signal contact <NUM> protrudes from the end of the first insulating part 228a where the depression <NUM> is arranged.

Once the inner signal contacts <NUM> are arranged in the cavities <NUM>, the inner signal contacts <NUM> are slid in an axial direction <NUM> along the first insulating part 228a into an end position (see <FIG>) in which the funnel-shaped reception section <NUM> of each inner signal contact <NUM> is form fittingly received in its corresponding depression <NUM> of the first insulating part 228a. Also, by sliding the inner signal contacts <NUM> in the axial direction <NUM>, the funnel-shaped end sections <NUM> (see <FIG>) of the inner signal contacts <NUM> may be widened by means of ribs <NUM>, if ribs <NUM> are arranged in a front opening <NUM> of the first insulating part 228a (see also <FIG>).

<FIG> depicts to a frontal view of the reception section <NUM>. After sliding the inner signal contacts <NUM> in the axial direction <NUM>, the funnel-shaped reception section <NUM> of each inner signal contact <NUM> is form fittingly received in its corresponding depression <NUM> of the first insulating part 228a. More specifically, the first insulating part 228a and the reception section <NUM> of the signal contact <NUM> are in contact with each other in an interference region <NUM>. In this interference region <NUM>, the relatively softer material of the first insulating part 228a gets pushed aside and, thus, is deformed by the reception section <NUM>, this deformation generating a retention force holding the signal contact <NUM> in place. With time, the deformed material of the first insulating part 228a will relax and the retention force decrease, but then the second insulating part 228b (shown in <FIG>) will have been mounted to the first insulation part 228a, thereby fully enclosing and fixing the reception section <NUM> within the insulating element <NUM>.

<FIG> depicts a step of pinching a second insulating part 228b to an assembly of the first insulating part 228a and the inner signal contacts <NUM>. After the inner signal contacts <NUM> have been brought into their end position in the first insulating part 228a, the second insulating part 228b is pinched, for example radially, onto the first insulating part 228a. The first insulating part 228a and the second insulating part 228b may be fixed together using press fit elements <NUM>, as described above for Figs. 13A to 14D. It is to be understood that the first insulating part 228a and the second insulating part 228b may be fixed together by other means, for example as described above for <FIG>.

The second insulating part 228b has an end cap <NUM> which includes a funnel-shaped connection opening <NUM> for each inner signal contact <NUM>, i.e. two funnel-shaped connection openings <NUM> in the present example. The end cap <NUM> may fix the inner signal contacts <NUM> against movement in the axial direction <NUM>. Each of the two funnel-shaped connection openings <NUM> of the end cap <NUM> is associated with a respective reception section <NUM> of the inner signal contacts <NUM>. The funnel-shaped connection openings <NUM> of the end cap <NUM> and the respective reception section <NUM> of the inner signal contacts <NUM> are aligned in an assembled state of the connector assembly <NUM>, i.e. when the second insulating part 228b is pinched onto the first insulating part 228a.

The inner signal contacts <NUM>, in particular the tube-like connection portions <NUM> of the inner signal contacts <NUM>, each include a welding opening <NUM>, also referred to as a first welding opening <NUM>. Likewise, the second insulating part 228b of the insulating element <NUM> includes at least one welding opening <NUM>, also referred to as a second welding opening <NUM>. It is to be understood that, additionally or alternatively, the first insulating part 228a of the insulating element <NUM> may include at least one welding opening <NUM> (see <FIG>). In the embodiment shown in <FIG>, the second insulating part 228b includes two welding openings <NUM>, each associated with a respective first welding opening <NUM> of the inner signal contacts <NUM>. Each of the first welding openings <NUM> of the inner signal contacts <NUM> and the respective second welding opening <NUM> of the second insulating part 228b are aligned in an assembled state of the connector assembly <NUM>, i.e. when the second insulating part 228b is pinched onto the first insulating part 228a. The assembled state of the connector assembly <NUM> is shown in <FIG>.

<FIG> depicts a cross-sectional side view of the connector assembly <NUM>. The inner signal contact <NUM> is completely surrounded by the first insulating part 228a and the second insulating part 228b, wherein the funnel-shaped end section <NUM> of the inner signal contact <NUM> is arranged in a front opening <NUM> of the first insulating part 228a. The funnel-shaped reception section <NUM> of the elongated inner signal contact <NUM> is arranged in the depression <NUM> defined by the first and second insulating parts 228a, 228b. Thereby, the inner signal contact <NUM> is fixed against movement in the axial direction <NUM>. The funnel-shaped connection opening <NUM> at the end cap <NUM> of the second insulating part 228b and the funnel-shaped reception section <NUM> of the inner signal contact <NUM> are aligned. The funnel-shaped connection opening <NUM> and the funnel-shaped reception section <NUM> may facilitate an insertion of a conductor (see <FIG>) into the tube-like connection portion <NUM> of the elongated inner signal contact <NUM>.

<FIG> depicts a step of sliding a first outer shielding contact <NUM> onto the connector assembly <NUM>. The first outer shielding contact <NUM> has at least one welding opening <NUM>, also referred to as a third welding opening <NUM>. The at least one third welding opening <NUM> is located at a first connection end portion <NUM> of the first outer shielding contact <NUM>. In the embodiment shown in <FIG>, the first outer shielding contact <NUM> includes two welding openings <NUM>, each of which is associated with a respective second welding opening <NUM> of the second insulating part 228b.

<FIG> depicts a perspective view of the connector assembly <NUM> with the first outer shielding contact <NUM> in an assembled state. The first welding openings <NUM> of the inner signal contacts <NUM>, the respective second welding openings <NUM> of the second insulating part 228b and the respective third welding openings <NUM> of the first outer shielding contact <NUM> are aligned in the assembled state of the connector assembly <NUM>.

The first outer shielding contact <NUM> further includes the second connection end portion <NUM> of the first outer shielding contact <NUM> to fix a cable <NUM> (not shown in <FIG>) to the first outer shielding contact <NUM>, as will be described further below.

The first insulating part 228a further includes at least one press fit spike <NUM>, in particular two opposite arranged press fit spikes <NUM> which protrude from the first insulating part 228a perpendicularly to the axial direction <NUM>. The press fit spikes <NUM> are configured to secure the insulating element <NUM> to the first connection end portion <NUM> of the first outer shielding contact <NUM>. To this end, the first outer shielding contact <NUM> defines at least one gap <NUM> at the first connection end portion <NUM> configured to receive the at least one press fit spike <NUM> of the first insulating element 228a, in the present example two U-shaped gaps <NUM> located on opposite sides of the first connection end portion <NUM> of the first outer shielding contact <NUM>. The first connection end portion <NUM> of the first outer shielding contact <NUM> is slid onto the insulating element <NUM> in the axial direction <NUM>, in particular onto the end cap <NUM> of the second insulating part 228b of the insulating element <NUM> such that each of the press fit spikes <NUM> is completely received in a press fit manner by the respective gap <NUM> on the first connection end portion <NUM> of the first outer shielding contact <NUM>.

<FIG> depicts a side view of the connector assembly <NUM> with the outer shielding contact <NUM> in the assembled state. The press fit spikes <NUM> may be formed as cuboidal elements having protrusions <NUM> that protrude over the surfaces of the cuboidal elements. The gaps <NUM> of the first outer shielding contact <NUM> may be formed as U-shaped recesses configured to receive the press fit spikes <NUM> of the first insulating part 228a. A cross-sectional dimension of the gaps <NUM> may be substantially the same as a cross-sectional dimension of the corresponding press fit spike <NUM> (the protrusions <NUM> not considered). When the insulating element <NUM> and the first connection end portion <NUM> of the first outer shielding contact <NUM> are assembled, the press fit spikes <NUM> are inserted into the corresponding cuboidal recesses or gaps <NUM> of the first outer shielding contact <NUM>. The press fit spikes <NUM> are secured in the gaps <NUM> by means of the protrusions <NUM>. More specifically, the press fit spikes <NUM> have to be pressed into the gaps <NUM> since the protrusions <NUM> lead to a cross-sectional dimension of the press fit spikes <NUM> greater than that of the gaps <NUM>.

<FIG> depict steps of wire conditioning after a trimmed cable braid <NUM> of the cable <NUM> has been back folded over a crimped ferrule <NUM> (see <FIG>). The cable <NUM> may include two twisted wires which are covered by a wire insulation <NUM>. In a first step, the wires are untwisted and flattened (<FIG>). In a next step, the wire insulation <NUM> is removed from end sections of the wires in order to strip end sections of the wire conductors <NUM> (<FIG>), while the wire insulation <NUM> may still cover a part of the wires adjacent to the crimped ferrule <NUM> (not shown in <FIG>). As mentioned before, the conductors <NUM> may be formed from strands. In a next step, the stripped ends of the conductors <NUM> are zero cut, for example, with heat to melt the strand ends to each other (<FIG>). In a next step, the wires are preformed into a U-shape (<FIG>). In a final step, the stripped wire strands <NUM> are soldered or resistance-welded into solid conductor ends.

<FIG> show the mounting of the cable <NUM> to the pre-assembled connector assembly <NUM>. In <FIG>, the cable <NUM> is inserted in the axial direction <NUM> into the second connection end portion <NUM> of the first outer shielding contact <NUM>, such that each of the stripped ends of the conductors <NUM> is inserted into a respective one of the tube-like connection portions <NUM> of the elongated inner signal contacts <NUM> (see also <FIG>). <FIG> shows a final position of the cable <NUM> in the second connection end portion <NUM> of the first outer shielding contact <NUM>, in which the inner crimp ferrule <NUM> of the cable <NUM> is completely surrounded by the second connection end portion <NUM> of the first outer shielding contact <NUM>.

The first outer shielding contact <NUM> includes a middle connection part <NUM> located between the first connection end portion <NUM> and the second connection end portion <NUM> of the first outer shielding contact <NUM>. The middle connection part <NUM> is configured to receive the conductors <NUM> (see <FIG>) of the cable <NUM> when the cable <NUM> is inserted into the second connection end portion <NUM> of the first outer shielding contact <NUM>.

<FIG> shows a cross-sectional view of the middle connection part <NUM> along a sectional plane E-E of <FIG> of the first outer shielding contact <NUM>. The middle connection part <NUM> defines two tunnels <NUM>, one for each conductor <NUM>, which serve to guide the stripped ends of the conductors <NUM> into the respective elongated inner signal contact <NUM> (not shown in <FIG>) when the cable <NUM> is inserted into the connector assembly <NUM> (<FIG>).

<FIG> show cross-sectional views of the connector assembly <NUM>. The tunnels <NUM> are separated by a partition wall <NUM> which serves to align the conductors <NUM> with the respective connection opening <NUM> of the end cap <NUM> of the second insulating part 228b (not shown in <FIG>). When the cable <NUM> is fully inserted, the cable <NUM> is fixed to the first outer shielding contact <NUM> by crimping the second connection end portion <NUM> of the first outer shielding contact <NUM> to the cable <NUM> (<FIG>), thereby increasing an overlapping of parts of the second connection end portion <NUM>.

Furthermore, when the cable <NUM> is fully inserted, the stripped ends of the conductors <NUM> are positioned in the tube-like connection portion <NUM> such that they can be accessed through the aligned welding openings <NUM>, <NUM>, <NUM> of the inner signal contact <NUM>, the second insulating part 228b and the first outer shielding contact <NUM> (<FIG>, <FIG>). Thereby, the conductors <NUM> can be connected to the inner signal contacts <NUM> via laser welding through the first welding opening <NUM>, the at least one second welding opening <NUM> and the at least one third welding opening <NUM>, as shown in <FIG>. As a result of the welding (<FIG>), the first welding openings <NUM> of the inner signal contacts <NUM>, the second welding openings <NUM> of the second insulating part 228b and the third welding openings <NUM> of the first outer shielding contact <NUM> are closed by a weld spot.

Thereafter, a second outer shielding contact <NUM> is slid onto the connector assembly <NUM> in an axial direction <NUM> (<FIG>), such that it surrounds the first connection end portion <NUM> of the first outer shielding contact <NUM> in the assembled state. The second outer shielding contact <NUM> has a plurality of shielding contacts <NUM>. As shown in <FIG>, the second outer shielding contact <NUM> is fixed to the first outer shielding contact <NUM> via welding spots <NUM> by welding, for example by laser welding.

As shown in <FIG>, the crimped second connection end portion <NUM> of the first outer shielding contact <NUM> may also be secured via welding spots <NUM> by welding, for example by laser welding.

<FIG> show an alternative cable assembly sequence. The steps described above in connection with <FIG> are generally the same for this alternative cable assembly sequence. However, in this alternative cable assembly sequence, an alternative second outer shielding contact <NUM> is slid onto the connector assembly <NUM> prior to inserting the cable <NUM> and welding (<FIG>). This alternative second outer shielding contact <NUM> differs from the above described second outer shielding contact <NUM> in that it has at least one welding opening <NUM>, also referred to as a fourth welding opening <NUM>. In the present example, the alternative second outer shielding contact <NUM> has two welding openings <NUM>, each one associated with a respective third welding opening <NUM> of the first outer shielding contact <NUM>, such that, in the assembled state, the first to fourth welding openings <NUM>, <NUM>, <NUM> and <NUM> are aligned for each inner signal contact <NUM>.

Once the cable <NUM> has been fully inserted into the second connection end portion <NUM> of the first outer shielding contact <NUM> as described before (<FIG>) and the second connection end portion <NUM> of the first outer shielding contact <NUM> has been crimped to the cable <NUM> and, optionally, secured via welding spots <NUM>, each conductor <NUM> is connected to the respective inner signal contact <NUM> via laser welding through the respective first to fourth welding openings <NUM>, <NUM>, <NUM> and <NUM>, as shown in <FIG>. As a result of this welding process, the first to fourth welding openings <NUM>, <NUM>, <NUM> and <NUM> will be closed by weld spots <NUM> (<FIG>).

The design of the connector assembly as described herein may eliminate safety relevant risks, such as a damaged interface during mating and electrical short circuits within the inner signal contacts <NUM> and/or in an application of a customer. Additionally, laser welding the conductors <NUM> to the inner signal contacts <NUM> may result in the best electrical and mechanical connection one can achieve. This kind of connection may allow a signal contact outer contour to be circular along a connection portion <NUM>, for example a wire termination section. A circular outer contact contour may be an ideal form for data transmission. Furthermore, laser welding is contactless and as such may enable further miniaturization with more design freedom to optimize dimensions in favor of data transmission.

Claim 1:
A connector assembly (<NUM>), comprising:
at least one elongated inner signal contact (<NUM>) defining an axial direction and having a tube-like connection portion (<NUM>), wherein the tube-like connection portion (<NUM>) comprises a first welding opening (<NUM>);
an insulating element (<NUM>) comprising a first insulating part (228a) and a second insulating part (228b), wherein the first insulating part (228a) defines at least one elongated cavity (<NUM>) designed to accommodate the at least one elongated inner signal contact (<NUM>),
characterized in that the second insulating part (228b) comprises at least one second welding opening (<NUM>), and in that the first welding opening (<NUM>) and the at least one second welding opening (<NUM>) are aligned in an assembled state of the connector assembly (<NUM>).