CN117559153A - Cable assembly with welded contacts - Google Patents

Abstract

A cable assembly includes a cable and a contact. The cable includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a distal end of the inner conductor is exposed at a first end. The contact is soldered at a first end to a terminal end of the inner conductor.

Description

Cable assembly with welded contacts

Technical Field

The present disclosure relates to a cable assembly, and more particularly to a cable assembly including contacts soldered to inner conductors of a wire assembly.

Background

Cable connector assemblies, such as coaxial cable connector assemblies, have been used in many automotive applications, such as navigation systems, infotainment systems, airbag systems, and other data transmission systems. A typical cable may include an inner conductor surrounded by a jacket. A typical coaxial cable includes an outer shield conductor, an inner center conductor, a dielectric, and an insulating jacket. The outer conductor and the inner conductor of the coaxial cable typically electrically interface with a mating coaxial cable through a coaxial connector assembly. Radio Frequency (RF) connectors, most commonly referred to simply as RF connectors, are commonly used to connect coaxial cables while providing a degree of shielding. With the proliferation of devices requiring high-speed data communications, the use of RF connectors for coaxial cables in automotive applications has greatly increased.

Typically, contacts connected to the inner conductor of the coaxial cable are mechanically adhered to the cable via crimping or soldering of the inner conductor to the contacts. For example, the contact may include wings that wrap around and crimp onto the inner conductor to ensure electrical and mechanical connection between the contact and the inner conductor. The contact may include a pin or terminal configured to interface with the terminal assembly to provide electrical contact between the inner conductor of the coaxial cable and the terminal assembly. The contacts are typically non-rigid and compliant and require orientation relative to the coaxial cable during the crimping (or soldering) operation. It would be beneficial to develop a contact that does not use crimping and/or welding between the contact and the inner conductor of the coaxial cable, but yet still interfaces with the terminal assembly.

Disclosure of Invention

According to one aspect, a cable assembly includes an insulated cable and a contact. The cable includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a distal end of the inner conductor is exposed at a first end. The contact is soldered at a first end to a terminal end of the inner conductor.

According to another aspect, a coaxial connection assembly includes a coaxial cable and a terminal assembly. The coaxial cable includes an inner conductor, a dielectric insulator, an outer conductor, and a jacket, wherein the outer conductor and the jacket are stripped from a first end, wherein at least a distal end of the inner conductor is exposed at the first end. The contact is soldered at a first end to a terminal end of the inner conductor. The outer terminal assembly includes a first opening for receiving a first end of the coaxial cable assembly, wherein the outer terminal includes a first insulator within the outer terminal assembly configured to receive a solder contact of the coaxial cable assembly.

Drawings

Fig. 1A is a side view of a coaxial cable assembly and a solder contact according to some embodiments;

fig. 1B is a side view of a central core of a coaxial cable assembly soldered to a contact, in accordance with some embodiments.

Fig. 2A is a side view of an external terminal assembly and a coaxial cable assembly with soldered contacts in accordance with some embodiments; fig. 2B is a side view of an outer terminal assembly mated with a coaxial cable assembly and an enlarged cross-sectional view illustrating a solder contact seated within the outer terminal assembly in accordance with some embodiments; fig. 2C is a side view of an external terminal assembly mated with a coaxial cable assembly and an enlarged cross-sectional view showing terminals associated with the external terminal assembly moved from a stage position to a seated position in contact with a solder contact in accordance with some embodiments; and fig. 2D is a side view illustrating crimping of a coaxial cable assembly to an external terminal assembly according to some embodiments.

FIG. 3A is a cross-sectional view of an outer terminal assembly showing terminals associated with the outer terminal assembly in a stage position, according to some embodiments; fig. 3B is a cross-sectional view of an outer terminal assembly showing terminals associated with the outer terminal assembly in a seated position in contact with a solder contact, in accordance with some embodiments.

Detailed Description

The present disclosure relates to a cable assembly, and more particularly to a cable assembly including contacts soldered to an inner conductor of the cable assembly. The cable assembly includes at least an inner conductor surrounded by an insulating jacket. In some embodiments, the first end of the cable is cut to expose an end portion of the inner conductor to which the contact is soldered. In some embodiments, the end portions are non-oriented, meaning that the contacts do not need to be oriented during soldering of the contacts to the end portions of the inner conductors. In some embodiments, the cable assembly is a coaxial cable assembly.

Fig. 1A and 1B are side views of a coaxial cable assembly 100 and a solder contact 112 according to some embodiments. In some embodiments, the coaxial cable assembly 100 includes an inner conductor 102, a dielectric insulator 104, a foil shield 106, an outer conductor 108, and a jacket 110. The contacts 112 are conductive contacts configured to be soldered to the inner conductor 102. Although coaxial cable assemblies are shown in fig. 1A and 1B, the discussion applies to simple cable assemblies that include only an inner conductor and an insulating sheath. Furthermore, the embodiments shown in fig. 1A and 1B show a coaxial cable assembly with, for example, a foil shield. In some embodiments, the coaxial cable assembly does not require a separate foil shield.

In some embodiments, a portion of the dielectric insulator 104 (and if included, a portion of the foil shield 106, as well as the outer conductor 108 and the jacket 110) is cut or stripped to expose the end portion 103 of the inner conductor 102. In some embodiments, the end portion is in a plane that is generally perpendicular to the longitudinal axis of the cable or coaxial cable. In some embodiments, only the end portion 103 of the inner conductor 102 is exposed (i.e., the circumferential surface of the inner conductor 102 is not exposed). The contact 112 is then soldered to the end portion 103 of the inner conductor 102 without any portion of the contact 112 contacting the outer periphery of the inner conductor 102. In other embodiments, a portion of the dielectric insulator 104 is stripped from the inner conductor, exposing a length of the inner conductor 102. In some embodiments, the length of the dielectric insulator 104 stripped from the inner conductor 102 is represented by a length d1 as shown in fig. 1B. As shown in fig. 1B, the contact 112 is soldered to the end portion 103 of the inner conductor 102. In some embodiments, the contact 112 is still in contact with only the end portion 103 of the inner conductor 102, even though at least a portion of the outer circumference of the inner conductor 102 may be exposed.

The embodiment shown in fig. 1A and 1B allows for stripping of extremely short lengths of dielectric insulator 104, as compared to typical crimping operations that require stripping longer lengths of dielectric insulator from the inner conductor to receive contacts. For example, in some embodiments, the length d1 is equal to or less than 1.0 millimeters (mm). In some embodiments, the length d1 is equal to or less than 0.7 millimeters. In some embodiments, the dielectric insulator 104 and the inner conductor 102 are cut to the same length, which results in a length d1 equal to zero. In some embodiments, the distance d1 between the end or stripped portion of the dielectric insulator 104 and the end of the inner conductor 102 is based on the geometry of the terminal assembly that the coaxial cable assembly 100 interfaces with. Reducing the length d1 improves the performance of the coaxial connection. In particular, since the solder contacts 112 enable relatively short interfaces, impedance mismatch introduced by the relatively long interfaces associated with the inner conductor and the crimp contact is reduced. The reduction in impedance mismatch improves the radio frequency performance of the interface between the coaxial assembly and the outer terminal assembly (shown in fig. 2A-2D).

In some embodiments, the solder contacts 112 comprise rigid and/or non-compliant materials. In some embodiments, at least the surface of the solder contact 112 is electrically conductive. For example, in some embodiments, the solder contacts 112 are rigid gold plated contacts. In other embodiments, other types of conductors may be used for the entire contact 112 or the surface of the solder contact 112.

In some embodiments, the solder contacts 112 are non-directional contacts (i.e., do not need to be oriented with respect to the coaxial cable assembly 100 or the inner conductor 102). For example, in the embodiment shown in fig. 1A and 1B, the solder contacts 112 are spherically shaped and may be soldered to the inner conductor 102 in any orientation. In other embodiments, the solder contacts 112 may be symmetrical about an axis or plane. For example, the solder contact 112 may be conical in shape with the base placed in contact with the inner conductor 102. In this embodiment, the weld contact 112 may need to be oriented along one axis or plane (e.g., to place the cone base in contact with the inner conductor 102), but need not be oriented along other axes or planes because the contact is symmetrical along that axis or plane. In other embodiments, the solder contacts 112 may have a geometry or shape that needs to be oriented with the coaxial cable assembly 100 (e.g., the contacts 112 may have an asymmetric shape that needs to be oriented along all axes or planes relative to the coaxial cable assembly 100).

In embodiments where the weld contact 112 is non-directional (e.g., spherical), the diameter of the weld contact 112 may be selected depending on the application. In some embodiments, the diameter of the solder contact 112 is less than the diameter of the inner conductor 102 to which it is soldered. In other embodiments, the diameter of the solder contact 112 is greater than the diameter of the inner conductor 102, but less than the diameter of the dielectric insulator 104. In other embodiments, the diameter of the solder contact 112 is simultaneously greater than the diameter of the inner conductor 102 and the dielectric insulator 104. In some embodiments, the diameter of the solder contact 112 is based on the geometry of the terminal assembly in which the solder contact 112 is seated during operation. In some embodiments, impact welding is used to weld the inner conductor 102 to the contact 112. One of the advantages of impact welding is the manufacturability of the impact welded component and the low cost associated with impact welding. For example, the contacts 112 may be soldered to the inner conductor 102 via an automated process flow. However, in other embodiments, other forms of welding may be used to mechanically secure the inner conductor 102 to the contact 112. In some embodiments, the welding of the inner conductor 102 to the contact 112 provides a bond that is greater in strength than the bond associated with the inner conductor 102.

Fig. 2A-2C are side views illustrating the installation of the coaxial cable assembly 100 within the external terminal assembly 200. The outer terminal assembly 200 includes an inner ferrule 202 and a contact assembly 204. In the embodiment shown in fig. 2A-2C, the outer terminal assembly 200 is a two-piece assembly that includes a contact assembly 204 that is separate from an inner ferrule 202. In other embodiments, these components may be integral (e.g., one-piece). As discussed with respect to fig. 1A and 1B, the coaxial cable assembly 100 includes an inner conductor 102, a dielectric insulator 104, a foil shield 106, an outer conductor 108, and a jacket 110. In the embodiment shown in fig. 2A and 2B, the contact 112 (in this case, a ball contact) has been soldered to the inner conductor 102.

During installation, the solder contacts 112, the inner conductor 102, the dielectric insulator 104, and the foil shield 106 are inserted into the inner ferrule 202. The previously flared outer conductor 108 is positioned around the outer surface of the inner ferrule 202 as shown in fig. 2A.

With respect to fig. 2B, an enlarged cross-sectional view of the outer terminal assembly 200 is shown, showing the solder contact 112 seated within the outer terminal assembly 200. In the cross-sectional view shown in fig. 2B, the insulator 206 is positioned within the outer terminal assembly 200 and is configured to receive the solder contact 112. In some embodiments, the insulator 206 has a geometry configured to receive the geometry of the solder contact 112. For example, if the solder contact 112 is spherical in shape having a first diameter, the geometry of the insulator 206 is configured to have a diameter large enough to receive the solder contact 112. In some embodiments, the insulator 206 may have features configured to provide tactile feedback to an operator regarding the seating of the welding contact 112 within the insulator 206. For example, in the embodiment shown in fig. 2B, the insulator locking edge 210 is configured to protrude slightly within the space configured to receive the solder contact 112. The insulator locking edge 210 acts as a stop that can flex in response to insertion of the contact 112 into the insulator 206 and then spring back into place, wherein this action provides a tactile response that can be felt by the operator. In the embodiment shown in fig. 2B, only the solder contact 112 and a portion of the inner conductor 102 extend into the insulator 206, as indicated by distance d 1.

Further, fig. 2B and 2C illustrate the seating of the terminals 208 configured to contact and form an electrical connection with the solder contacts 112. Fig. 2B shows the terminal 208 in a stage position (process position or ready position) in which the terminal 208 has not been in contact with the solder contact 112. Fig. 2C shows the terminal 208 in a seated position, wherein the terminal 208 has been moved into contact with the solder contact 112, thereby providing an electrical connection between the inner conductor 102 and the terminal 208. In some embodiments, the terminals 208 have a geometry selected based on the geometry of the solder contacts 112. For example, in the embodiment shown in fig. 2B and 2C, the terminal 208 has a geometry configured to place the terminal 208 in contact with the solder contact 112 but not interface with the inner conductor 102. For example, the terminal 208 may include a recess 212, the recess 212 being located on the bottom of the terminal 208 to prevent contact between the terminal 208 and the inner conductor 102. That is, in the present embodiment, the inner surface of the terminal 208 is in contact with the solder contact 112 along the side of the spherical conductor. In other embodiments, other types of terminals may be used to provide an electrical connection between the solder contact 112 and the terminal 208.

After the coaxial cable assembly 100 is seated within the outer terminal assembly 200, the outer conductor is crimped onto the inner ferrule 202 of the outer terminal assembly 200 via the outer ferrule 220. In the embodiment shown in fig. 2D, the outer ferrule 220 includes a first crimp 224 and a second crimp 226. The first crimp 224 surrounds the outer conductor 108 and is crimped to form a mechanical and electrical bond between the outer conductor 108 and the inner ferrule 202. The second crimp 226 surrounds the sheath 110 and is crimped to further secure the coaxial cable assembly 100 to the outer terminal assembly 200.

Fig. 3A and 3B are cross-sectional views of coaxial cable assembly 100 seated and crimped within outer terminal assembly 200 according to some embodiments. Specifically, fig. 3A shows the outer conductor 108 crimped to the inner ferrule 202 by the outer ferrule 110. In addition, the outer ferrule 220 is crimped onto the jacket 108, providing additional mechanical force to secure the coaxial cable assembly to the outer terminal assembly 200.

In the embodiment shown in fig. 3A, the outer terminal assembly 200 includes a first insulator 206 and a second insulator 222. In some embodiments, the second insulator 222 at least partially overlaps the first insulator 206 and surrounds at least a portion of the terminal 208. In the embodiment shown in fig. 3A, the terminals 208 are in a stage position (i.e., not in contact with the contacts 112). Movement of the second insulator 222 in a direction toward the contact 112 causes the terminal 208 to move from the staged position to a seated position in which the terminal 208 is in contact with the contact 112. The embodiment shown in fig. 3A and 3B illustrates a "tulip" arrangement associated with the first and second insulators 206, 222 and the terminal 208, wherein sliding movement of the second insulator 222 causes sliding engagement of the terminal 208 with the contact. In some embodiments, one or more features may be used to facilitate engagement between the terminals 208 and the contacts 112.

While the invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Discussion of possible embodiments

The following is a non-exclusive description of possible embodiments of the invention.

According to one aspect, a cable assembly includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a distal end of the inner conductor is exposed at a first end. The contact is soldered at a first end to a terminal end of the inner conductor.

The cable assembly of the preceding paragraph may optionally include, additionally and/or alternatively include any one or more of the following features, configurations and/or additional components.

For example, the contacts may be rigid and include conductive surfaces.

In some embodiments, the contact may be impact welded to the inner conductor.

In some embodiments, the contact may be symmetrical about an axis, wherein the contact is oriented with respect to the coaxial cable to be soldered to the inner conductor.

In some embodiments, the contacts may be spherical, non-directional contacts.

In some embodiments, the diameter of the contact may be greater than or equal to the diameter of the inner conductor.

In some embodiments, the cable assembly may be a coaxial cable assembly further comprising a dielectric insulator surrounding the inner conductor and an outer conductor surrounding the dielectric insulator, wherein the insulating jacket surrounds the outer conductor, wherein the outer conductor and the insulating jacket are stripped to expose the dielectric insulator at the first end.

In some embodiments, the outer dielectric insulator may be stripped from the inner conductor to expose a length of the inner conductor.

In some embodiments, the length of the exposed inner conductor may be less than or equal to 0.7 millimeters.

In some embodiments, the diameter of the contacts may be less than or equal to the diameter of the dielectric insulator.

According to another aspect, a coaxial connection assembly includes a coaxial cable and a terminal assembly. The coaxial cable includes an inner conductor, a dielectric insulator, a foil shield, an outer conductor, and a jacket, wherein the foil shield, the outer conductor, and the jacket are stripped from a first end, wherein at least a distal end of the inner conductor is exposed at the first end. The contact is soldered at a first end to a terminal end of the inner conductor. The outer terminal assembly includes a first opening for receiving a first end of the coaxial cable assembly, wherein the outer terminal includes a first insulator within the outer terminal assembly configured to receive a solder contact of the coaxial cable assembly.

The coaxial connection assembly of the preceding paragraph may optionally include, additionally and/or alternatively include any one or more of the following features, configurations and/or additional components.

For example, the first insulator may include an insulator locking edge that stops in response to the solder contact sitting within the first insulator.

In some embodiments, the outer terminal assembly may further comprise a terminal, wherein the terminal is movable between a staged position and a seated position, the terminal being in contact with the solder contact in the seated position.

In some embodiments, the outer terminal assembly further comprises a second insulator at least partially surrounding the terminal, wherein the second insulator is movable with the terminal between the stage position and the seated position.

In some embodiments, the outer terminal assembly may further comprise an inner ferrule, wherein at least the solder contact, the inner conductor, and the dielectric insulator are received within the inner ferrule, and wherein the outer conductor is placed over the outer ferrule, wherein the outer ferrule is crimped to the outer conductor and the inner ferrule to secure the coaxial cable assembly to the outer terminal assembly.

In some embodiments, the solder contact may be rigid and include a conductive surface, and wherein the solder contact is impact soldered to the inner conductor.

In some embodiments, the dielectric insulator may be stripped at the first end to expose a length of the inner conductor, wherein the exposed length of the inner conductor is less than or equal to 0.7 millimeters.

In some embodiments, the solder contact may be symmetrical about an axis, wherein the solder contact is oriented with respect to the coaxial cable to solder to the inner conductor.

In some embodiments, the solder contacts may be spherical, non-directional contacts.

In some embodiments, the diameter of the solder contact may be greater than or equal to the diameter of the inner conductor.

In some embodiments, the solder contact may have a diameter less than or equal to the diameter of the dielectric insulator.

Claims (21)

1. A cable assembly, comprising:

an inner conductor and an insulating sheath surrounding the inner conductor, wherein a distal end of the inner conductor is exposed at a first end; and

a contact soldered to a terminal end of the inner conductor at the first end.

2. The cable assembly of claim 1, wherein the contact is rigid and includes a conductive surface.

3. The electrical cable assembly of claim 1, wherein the contact is impact welded to the inner conductor.

4. The cable assembly of claim 1, wherein the contact is symmetrical about an axis, wherein the contact is oriented with respect to a coaxial cable to be soldered to the inner conductor.

5. The cable assembly of claim 1, wherein the contacts are spherical, non-directional contacts.

6. The cable assembly of claim 1, wherein the diameter of the contact is greater than or equal to the diameter of the inner conductor.

7. The cable assembly of claim 1, wherein the cable assembly is a coaxial cable assembly further comprising a dielectric insulator surrounding the inner conductor and an outer conductor surrounding the dielectric insulator, wherein the insulating jacket surrounds the outer conductor, wherein the outer conductor and the insulating jacket are stripped to expose the dielectric insulator at the first end.

8. The electrical cable assembly of claim 7, wherein an outer dielectric insulator is stripped from the inner conductor to expose a length of the inner conductor.

9. The cable assembly of claim 8, wherein the exposed inner conductor has a length of less than or equal to 0.7 millimeters.

10. The electrical cable assembly of claim 7, wherein the diameter of the contact is less than or equal to the diameter of the dielectric insulator.

11. A coaxial connection assembly comprising:

a coaxial cable assembly comprising a contact, an inner conductor, a dielectric insulator, an outer conductor, and a jacket, wherein the outer conductor and the jacket are stripped from a first end, wherein at least a distal end of the inner conductor is exposed at the first end, wherein the contact is soldered to a distal end of the inner conductor at the first end; and

an outer terminal assembly having a first opening for receiving the first end of the coaxial cable assembly, wherein the outer terminal includes a first insulator within the outer terminal assembly configured to receive the solder contact of the coaxial cable assembly.

12. The coaxial connection assembly of claim 11, wherein the first insulator includes an insulator locking edge that stops in response to the solder contact sitting within the first insulator.

13. The coaxial connection assembly of claim 11, wherein the outer terminal assembly further comprises a terminal, wherein the terminal is movable between a staged position and a seated position, wherein the terminal is in contact with the solder contact.

14. The coaxial connection assembly of claim 13, wherein the outer terminal assembly further comprises a second insulator at least partially surrounding the terminal, wherein the second insulator is movable with the terminal between the stage position and the seated position.

15. The coaxial connection assembly of claim 11, wherein the outer terminal assembly further comprises an inner ferrule, wherein at least the solder contact, the inner conductor, and the dielectric insulator are received within the inner ferrule, and wherein the outer conductor is placed over the outer ferrule, wherein an outer ferrule is crimped to the outer conductor and the inner ferrule to secure the coaxial cable assembly to the outer terminal assembly.

16. The coaxial connection assembly of claim 11, wherein the solder contact is rigid and includes a conductive surface, and wherein the solder contact is impact soldered to the inner conductor.

17. The coaxial connection assembly of claim 11, wherein the dielectric insulator is stripped at the first end to expose a length of the inner conductor, wherein the exposed length of the inner conductor is less than or equal to 0.7 millimeters.

18. The coaxial connection assembly of claim 11, wherein the solder contact is symmetrical about an axis, wherein the solder contact is oriented with respect to the coaxial cable to solder to the inner conductor.

19. The coaxial connection assembly of claim 11, wherein the solder contact is a spherical, non-directional contact.

20. The coaxial connection assembly of claim 11, wherein the diameter of the solder contact is greater than or equal to the diameter of the inner conductor.

21. The coaxial connection assembly of claim 20, wherein the solder contact has a diameter less than or equal to a diameter of the dielectric insulator.