Connector devices having increased weld strength and methods of manufacture
First Claim
1. A connector, comprising:
- a front shield shell having an axial passageway therethrough, the front shield shell comprising a material having a coefficient of thermal expansion such that the front shield shell has an expanded profile at a first temperature and a reduced profile at a second temperature, the second temperature being lower than the first;
a rear shield shell having a distal portion and a proximal portion, and an axial passageway extending therethrough, wherein the distal portion extends at least partially into the axial passageway of the front shield shell,wherein the front shield shell is dimensioned such that, when the rear shield shell is at the second temperature and the front shield shell is at the first temperature, the distal portion of the rear shield shell is receivable within the axial passageway of the front shield shell;
a boot member having an axial passageway therethrough extending from a proximal opening to a distal opening and a distal cavity at the distal opening, the distal cavity being dimensioned so as to fittingly receive the proximal portion of the rear shield shell such that an outer surface of the boot member is about flush with an outside surface of the front shield shell along a length of the connector; and
a plurality of terminals disposed within the front shield shell, the plurality of terminals electrically coupled to a cable through the rear shield shell and the boot member.
1 Assignment
0 Petitions
Accused Products
Abstract
Devices and methods of manufacture for improved connector plugs are provided herein. In one aspect, an exemplary connector plug comprises a shield shell having a proximal stepped-down portion and a boot member that fittingly receives the stepped-down proximal portion so that an outer surface of the distal shield shell and the boot member is about flush with a minimal or negligible space therebetween. In some embodiments, the shield shell comprises a separate front shield shell and a reduced profile rear shield shell welded together so as to provide the advantageous reduced profile and improved aesthetic appearance, while maintaining the structural integrity of the connector. In many embodiments, weld strength of the shield shells is improved by providing line-to-line contact between shield shells by using deflectable tabs and/or utilizing thermal expansion properties of one or both shield shells.
35 Citations
24 Claims
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1. A connector, comprising:
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a front shield shell having an axial passageway therethrough, the front shield shell comprising a material having a coefficient of thermal expansion such that the front shield shell has an expanded profile at a first temperature and a reduced profile at a second temperature, the second temperature being lower than the first; a rear shield shell having a distal portion and a proximal portion, and an axial passageway extending therethrough, wherein the distal portion extends at least partially into the axial passageway of the front shield shell, wherein the front shield shell is dimensioned such that, when the rear shield shell is at the second temperature and the front shield shell is at the first temperature, the distal portion of the rear shield shell is receivable within the axial passageway of the front shield shell; a boot member having an axial passageway therethrough extending from a proximal opening to a distal opening and a distal cavity at the distal opening, the distal cavity being dimensioned so as to fittingly receive the proximal portion of the rear shield shell such that an outer surface of the boot member is about flush with an outside surface of the front shield shell along a length of the connector; and a plurality of terminals disposed within the front shield shell, the plurality of terminals electrically coupled to a cable through the rear shield shell and the boot member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of manufacturing a connector, the method comprising:
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providing an open-ended front shield shell and a rear shield shell, the front shield shell having an expanded profile at a first temperature and a reduced profile at a second profile due to a coefficient of thermal expansion of a material comprising the front shield shell, the second temperature being lower than the first; heating the front shield shell to the first temperature; placing the rear shield shell within the front shield shell, while the front shield shell is at the first temperature and the rear shield shell is at the second temperature; positioning the rear shield shell relative to the front shield shell so that a distal portion of the rear shield shell is within the front shield shell and a proximal portion extends outside of the front shield shell; cooling the front shield shell to the second temperature so as to produce line-to-line contact between an inside surface of the front shield shell in the reduced profile and an outer surface of the rear shield shell; fixedly attaching the front shield shell and rear shield shell at the line-to-line contact between the front shield shell and the rear shield shell; and advancing a boot member over the proximal portion of the rear shield shell so that an outer surface of the boot is about flush with an outer surface of the front shield shell along a length of the connector. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
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Specification