Electrical connector and method of making same

• US 4,602,831 A
• Filed: 08/26/1985
• Issued: 07/29/1986
• Est. Priority Date: 09/26/1983
• Status: Expired due to Term

• Current Assignee: AMP Limited
• Original Assignee: AMP Limited
• Inventors: Lockard, Joseph L.
• Primary Examiner(s): Weidenfeld, Gil
• Assistant Examiner(s): Bishop, Steven C.
• Application Number:
  US06/769,552
• Time in Patent Office: 337 Days
• Field of Search: 339/14 R, 339/91 R, 339/102 R, 339/103 M, 339/107, 339/176 M, 339/184 R, 339/184 M, 339/186 R, 339/186 M, 339/195 R, 339/196 R, 339/198 G , 339/198 GA, 339/218 R, 339/218 M, 339/143 R, 339/275 R, 339/276 R, 339/275 T, 339/276 T, 29/860, 29/857, 29/858, 333/33, 333/260
• US Class Current: 439/108
• CPC Class Codes: H01R 13/627 Snap or like fastening
• CPC Class Codes: H01R 13/6592 the conductive member being a shielded cable
• CPC Class Codes: H01R 13/6596 the conductive member being a metal grounding panel
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 24/22 with additional earth or shield contacts
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding

Abstract

An electrical plug connector comprises a dielectric contact-carrying member having signal contact members secured to one side of the contact-carrying member at spaced intervals therealong. A ground contact member is secured to the other side of the contact carrying member with contact sections of the signal contact members and the ground contact member extending from a front end of the contact-carrying member. Conductor-connecting sections of the signal and ground contact members extending along the contact-carrying member. Signal conductors and ground conductors of electrical cables are electrically connected respectively to the conductor-connecting sections of the signal contact members and the ground contact member. A dielectric housing member is secured onto the contact-carrying member and part of the electrical cables so that the contact members from their contact sections to their conductor-connecting sections are covered.

Claims

1. An electrical connector for signal conductor means and ground conductor means of electrical cable means for use in transmitting electrical signals with high reliability and uniformity, comprising:

contact assembly means including dielectric contact-carrying means having signal contact means disposed on one side and ground contact means disposed on the other side of said contact-carrying means, securing means provided by said contact-carrying means for each said signal and ground contact means securing each said signal and ground contact means in position against the respective sides of said contact-carrying means, signal contact section means of said signal contact means and ground contact section means of said ground contact means disposed proximate a front end of said contact-carrying means, and said signal contact means and said ground contact means having respective conductor-connecting section means;

electrical cable means having signal conductor means and ground conductor means, a plurality of end portions of said signal conductor means and ground conductor means extending forwardly therefrom with at least one said ground conductor means associated with each said signal conductor means, said signal conductor end portions electrically connected to respective said signal conductor-connecting section means and said ground conductor end portions electrically connected to said ground conductor-connecting section means;

dielectric housing means molded around said contact assembly means, said conductor end portions and section means of said electrical cable means thereby sealing the terminations of said signal and ground conductor means to respective said signal and ground contact means and insulating said conductor end portions; and

means provided by said dielectric housing means engaging said section means of said cable means and providing nondistorting strain relief for said cable means whereby the electrical performance characteristics of said electrical cable means are maintained.

2. An electrical connector as set forth in claim 1 wherein said housing means includes a rear section having a first portion molded around a first section of said cable means proximate said conductor end portions, a second portion molded around a second section of said cable means spaced rearwardly from said first section, and at least two longitudinal third portions joining together said first and second portions and forming therebetween at least one aperture defining a third section of said cable means which is not engaged by said housing means, thereby minimizing engagement of said housing means with said cable means.

3. An electrical connector as set forth in claim 1 wherein said contact-carrying means includes a conductor-positioning section means at a rearward end thereof, said conductor-connecting section means of each said signal contact means and said ground contact means extend along said contact-carrying means forwardly of said conductor-positioning section means thereof and in alignment with respective conductor-positioning means thereof, and said end portions of said signal and ground conductor means are disposed in respective said conductor-positioning means rearward from respective terminations thereof to said signal and ground contact means.

4. An electrical connector as set forth in claim 1 wherein the one side of said contact-carrying means has spaced recesses in which planar central sections of said signal contact means are disposed, first said securing means comprise first projections in said recesses extending through holes in said planar central sections, second said securing means comprise second projections extending outwardly from the other side of said contact-carrying means and extending through holes in an elongated planar section of said ground contact means, outer ends of said first and second projections being disrupted thereby securing said signal contact means and said ground contact means to said contact-carrying means.

5. An electrical connector for signal conductor means and ground conductor means of electrical cable means for use in transmitting electrical signals with high reliability and uniformity, comprising:

an electrical contact assembly including a dielectric contact-carrying member having a plurality of signal contact members disposed on one side of said contact-carrying member at spaced intervals therealong and a ground contact member disposed on the other side thereof, first and second securing means provided by said contact-carrying member respectively securing each said signal contact member and said ground contact member against the respective sides of said contact-carrying member, signal contact sections of said signal contact members and ground contact sections of said ground contact member disposed proximate a front end of said contact-carrying member, and conductor-connecting sections of each said signal contact members and said ground contact member extending along said contact-carrying member;

electrical cable means having signal conductor means and ground conductor means, a plurality of end portions of said signal conductor means and ground conductor means extending forwardly therefrom with at least one said ground conductor means associated with each said signal conductor means, said signal conductor end portions electrically connected to respective conductor-connecting sections of said signal contact members and said ground conductor end portions electrically connected to said conductor-connecting sections of said ground contact member;

a dielectric housing molded around said electrical contact assembly, said conductor end portions and section means of said electrical cable means thereby sealing the terminations of said signal and ground conductor means to respective said signal and ground contact members and insulating said conductor end portions; and

means provided by said dielectric housing engaging said section means of said cable means and providing nondistorting strain relief for said cable means whereby the electrical performance characteristics of said cable means are maintained.

6. An electrical connector as set forth in claim 5 wherein said housing includes a rear section having a first portion molded around a first section of said cable means proximate said conductor end portions, a second portion molded around a second section of said cable means spaced rearwardly from said first section, and at least two longitudinal third portions joining together said first and second portions and forming therebetween at least one aperture defining a third section of said cable means which is not engaged by said housing, thereby minimizing engagement by said housing with said cable means.

7. An electrical connector as set forth in claim 5 wherein said contact-carrying member is thin, flat and substantially disposed in a plane forwardly of said electrical cable means, said signal and ground contact members and said signal and ground conductor end portions are substantially disposed along said plane, and said dielectric housing thereover is therefor moldable into a thin, flat substantially planar configuration, whereby said connector is therefor substantially thin, flat and disposed in a plane forwardly of said electrical cable means enabling close spacing of several adjacent ones of said connectors in an assembly to form a matrix of said signal and ground contact sections at forward ends thereof.

8. An electrical connector as set forth in claim 5 wherein said electrical cable means are individual cables and said dielectric housing spaces and supports said cables.

9. An electrical connector according to claim 5 wherein the dielectric constant of said contact-carrying member and of said housing is substantially the same as that of the outer dielectric jacket of said electrical cable means.

10. An electrical connector as set forth in claim 5 wherein said contact-carrying member includes a conductor-positioning section at a rearward end thereof, said conductor-connecting sections of each said signal contact members and said ground contact member extend along said contact-carrying member forwardly of said conductor-positioning section thereof and in alignment with respective conductor-positioning means thereof, and said end portions of said signal and ground conductor means are disposed in respective said conductor-positioning means rearward from respective terminations thereof to said signal and ground contact members.

11. An electrical connector as set forth in claim 10 wherein said conductor-connecting sections are planar and are disposed along said contact-carrying member forward of and adjacent said conductor-positioning means thereof.

12. An electrical connector as set forth in claim 10 wherein said conductor-connecting sections of said signal contact members are ferrule sections and said one side of said contact-carrying member has aligning projections proximate said conductor-positioning section and adjacent said ferrule sections which align said ferrule sections with respective said conductor-positioning means to receive said signal conductor end portions.

13. An electrical connector as set forth in claim 10 wherein said conductor-positioning means comprise channels, said conductor-connecting sections of said signal and ground contact members have slots aligned with said channels, along which said channels and said slots are disposed said signal and ground conductor end portions respectively.

14. An electrical connector as set forth in claim 13 wherein said channels have beveled guiding surfaces for said signal and ground conductor end portions.

15. An electrical connector as set forth in claim 5 wherein the one side of said contact-carrying member has spaced recesses in which planar central sections of said signal contact members are disposed, said first securing means comprise first projections in said recesses extending through holes in said planar central sections, said second securing means comprise second projections extending outwardly from the other side of said contact-carrying member and extending through holes in an elongated planar section of said ground contact member, outer ends of said first and second projections being disrupted thereby securing said signal contact members and said ground contact member to said contact-carrying member.

16. An electrical connector as set forth in claim 5 wherein said conductor-connecting sections of said signal contact members are ferrule sections having slots along which the signal conductor end portions are disposed and welded to said signal contact members, each said slot having a width slightly less than the diameter of a said signal conductor.

17. An electrical connector as set forth in claim 5 wherein said conductor-connecting sections of said ground contact member are slots into which the ground conductor end portions are disposed and welded to said ground contact member, each said slot having a width slightly less than the diameter of a said ground conductor.

18. An electrical connector as set forth in claim 5 wherein said planar section of said ground contact member has openings opposed from respective planar central sections of said signal contact members and designed in size so that the impedance of the assembly approximates the characteristic impedance of the electrical cable means.

19. An electrical connector as set forth in claim 5 wherein said conductor-connecting sections are ferrule sections extending outwardly from a back end of said contact-carrying member.

20. An electrical connector as set forth in claim 5 wherein said signal contact sections and said ground contact sections are tab contact sections extending forwardly from a front end of said housing aligned in a common plane.

21. An electrical connector according to claim 20 wherein said tab contact sections are thicker than said planar central sections and said elongated planar section respectively.

22. An electrical connector as set forth in claim 20 wherein said tab contact sections are formed by bent back metal layers, an inwardly-directed projection of one of the layers adjacent an inner end of the contact sections spaces the layers, and said housing is molded around free ends of the bent back layers thereby securing them therein.

23. An electrical connector as set forth in claim 5 wherein said electrical cable means are three-lead cables and two said ground conductor means are associated with each said signal conductor means.

24. An electrical connector as set forth in claim 5 wherein said electrical cable means are three-lead coaxial cables.

25. An electrical plug connector for electrical cable means for use in transmitting electrical signals with high reliability and uniformity, comprising:

an electrical contact assembly including a substantially thin and flat dielectric contact-carrying member substantially disposed in a plane, said contact-carrying member having a front end and a back end and conductor-positioning channels proximate said back end, said electrical contact assembly also having a plurality of signal contact members secured in position by first securing means to one side of said contact-carrying member at spaced intervals therealong forward of said conductor-positioning channels and a ground contact member secured in position by second securing means to the other side forward of said conductor-positioning channels, each of said signal contact members having at least a signal contact section proximate said front end and a conductor-connecting section proximate a respective said conductor-positioning channel and said ground contact member having at least a plurality of ground contact sections proximate said front end and a plurality of conductor-connecting sections proximate respective said conductor-positioning channels, said signal contact sections of said signal contact members and ground contact sections of said ground contact member extending forwardly from said front end of said contact-carrying member, and said conductor-connecting sections of said signal and ground contact members have slots aligned with respective said conductor-positioning channels;

electrical cable means disposed in the plane of said contact-carrying member rearwardly thereof and having signal conductor means and ground conductor means, stripped end portions of which conductor means extend along respective said conductor-positioning channels substantially parallel to said plane of said contact-carrying member from a rearward end thereof, with said end portions of said signal conductor means disposed along said slots of said signal contact members and welded thereto, and said end portions of said ground conductor means disposed along said slots of said ground contact member and welded thereto, each said slot having a width slightly less than the diameter of a respective said conductor means disposed therealong; and

a dielectric housing molded securely around said electrical contact assembly rearwardly from said signal and ground contact sections and around section means of said electrical cable means, thereby sealing the terminations of said signal and ground conductor means to respective said signal and ground contact members, providing means for nondistorting strain relief for said cable means whereby the electrical performance characteristics of said cable means are maintained.

26. An electrical plug connector as set forth in claim 25 wherein said housing includes a rear section having a first portion molded around a first section of said cable means proximate said conductor end portions, a second portion molded around a second section of said cable means spaced rearwarly from said first section, and at least two longitudinal third portions joining together said first and second portions and forming therebetween at least one aperture defining a third section of said cable means which is not engaged by said housing thereby minimizing engagement by said housing with said cable means.

27. An electrical plug connector as set forth in claim 25 wherein said one side of said contact-carrying member has aligning projections forward of said conductor-positioning channels and adjacent said conductor-connecting sections of said signal contact members which align them and thereby align said slots thereof with said channels to receive said signal conductors.

28. An electrical plug connector as set forth in claim 25 wherein said one side of said contact-carrying member has spaced recesses in which planar central sections of said signal contact members are disposed and said first securing means comprise oblong first projections in said recesses extending through holes in said planar central sections, and said other side of said contact-carrying member includes second projections comprising said second securing means and extending outwardly through holes in an elongated planar section of said ground contact member, outer ends of said first and second projections being disrupted thereby securing said signal contact members and said ground contact member to said contact-carrying member.

29. An electrical plug connector as set forth in claim 25 wherein said elongated planar section of said ground contact member has openings opposed from respective said planar central sections of said signal contact members and designed in size so that the impedance of the assembly approximates the characteristic impedance of the cables.

30. An electrical connector for three-lead electrical cables for use in transmitting electrical signals with high reliability and uniformity, comprising:

an electrical contact assembly including signal contact members having contact sections and terminated to respective end portions of signal conductors of three-lead electrical cables and at least one ground contact member having at least one contact section and terminated to end portions of ground conductors of said electrical cables, said electrical contact assembly further including dielectric means between said signal contact members and said at least one ground contact member, and spaced forwardly from insulated portions of said three-lead electrical cables; and

a dielectric housing molded securely around said electrical contact assembly, said conductor end portions, and section means of said electrical cables thereby sealing the terminations of said signal and ground conductors to respective said signal and ground contact members and insulating said conductor end portions, said housing including a rearward cable-engaging section substantially spaced rearwardly from said electrical contact assembly such that said housing substantially does not engage said three-lead cables between said rearward cable-engaging section and said electrical contact assembly, thereby providing a nondistorting strain relief for said three-lead cables whereby the electrical performance characteristics of said three-lead cables are maintained.

31. An assembly of electrical connectors for electrical cable means for transmitting electrical signals with high reliability and uniformity, comprising a connector-receiving means and a plurality of electrical connector means securable therein adjacent each other, each of said electrical connector means comprising a contact assembly means and a dielectric housing means secured on said contact assembly means wherein:

said contact assembly means includes a dielectric contact-carrying member, a plurality of signal contact members secured in position against one side thereof by first securing means, a ground contact means secured in position against the other side thereof by second securing means, end portions of signal conductor means of said electrical cable means being electrically connected to respective said signal contact members, and end portions of ground conductor means of said electrical cable means being electrically connected to said ground contact means;

said contact assembly means is substantially thin and flat and disposed in a plane;

contact sections of said signal contact members and said ground contact means are disposed in the plane of said contact assembly means proximate a front end thereof and are in alignment with and spaced from each other in a preselected arrangement;

said electrical cable means extend outward from a rearward end of said contact assembly means and disposed in said plane of said contact assembly; and

said dielectric housing means is molded securely around said contact assembly means, said conductor end portions, and section means of said electrical cable means thereby sealing the terminations of said signal and ground conductors to respective said signal members and said ground contact means and insulating said conductor end portions, said housing means including a means engaging said section means of said electrical cable means and providing nondistorting strain relief for said cable means whereby the electrical performance characteristics of said cable means are maintained;

said housing means is thin, flat and planar whereby each said connector means is therefor substantially thin, flat and disposed in a plane forwardly of said electrical cable means enabling close spacing of said connector means in said assembly to form a matrix of said signal and ground contact sections of forward ends thereof; and

said dielectric housing means and said connector-receiving means have cooperating securing means thereon.

32. An assembly of electrical connectors as set forth in claim 31 wherein said cooperating securing means comprises cooperating latching means.

33. An assembly of electrical connectors as set forth in claim 31 wherein said dielectric housing means has latching means extending laterally therefrom and disposed in said plane of said contact assembly means.

34. An assembly of electrical connectors as set forth in claim 33 wherein said latching means are flexible latch members integral with said housing which comprise front and rear leg portions joined to each other at a point spaced from said housing and joined to said housing proximate front and rear ends respectively thereof, said point of joining of said front and rear legs including a rearwardly facing latching surface to latchingly engage an associated engaging surface on said connector-receiving member.

35. An assembly of electrical connectors as set forth in claim 34 wherein said latch members are of different widths to polarize the insertion of a said connector means within said connector-receiving member.

36. A method of assembling an electrical connector for electrical cable means for use in transmitting electrical signals with high reliability and uniformity, comprising the steps of:

placing planar central sections of signal contact members in adjacent recesses on one side of a dielectric contact-carrying member with signal contact sections of said signal contact members disposed proximate a front end of said contact-carrying member;

securing said signal contact members in position against said contact-carrying member by first securing means on said contact-carrying member;

placing a planar section of a ground contact member adjacent the other side of said contact-carrying member with ground contact sections of said ground contact member disposed proximate said front end of said contact-carrying member;

securing said ground contact member in position against said contact-carrying member by second securing means in said contact-carrying member;

terminating stripped end portions of signal and ground conductors of electrical cable means to conductor-connecting sections of said signal contact members and said ground contact member respectively rearward of said planar central sections and said planar section respectively; and

molding a dielectric housing sealingly around said contact-carrying member, said planar central sections of said signal contact members, said planar section of said ground contact member, said conductor-connecting sections thereof, said terminations, said conductor end portions, and section means of said electrical cable means to provide nondistorting strain relief therefor, whereby the electrical performance characteristics of the electrical cable means are maintained.

37. The method as set forth in claim 36 wherein said first securing means comprise projections extending outward from said one side in said recesses and through corresponding holes in said planar central sections of said signal contact members, and said second securing means comprise projections extending outward from said other side and through corresponding holes in said planar section of said ground contact member, and said securing steps comprise enlarging outer ends of said projections.

38. The method as set forth in claim 36 wherein said molding of said dielectric housing includes positioning said contact-carrying member and said signal and ground contact members secured thereto in a mold which includes cable-positioning members with said electrical cable means positioned thereby.