Abstract: A coaxial cable assembly includes an inner conductor having an outer circumferential surface, wherein the inner conductor terminates in a tip having a planar surface substantially perpendicular to a longitudinal axis of the inner conductor. The coaxial cable assembly further includes an insulator located around the outer circumferential surface of the inner conductor and a contact welded to the planar surface of the tip of the inner conductor.

Abstract: An electrical connector assembly terminal modules configured to contain electrical terminals connected to one or more electrical cables, an inner module frame in which terminal modules are secured, and an outer housing having cantilevered locking arms with primary surfaces and secondary surfaces on inner sides of the locking arms to secure the inner module frame to the female outer housing. Latch surfaces of the inner module frame engage the primary surfaces when the inner module frame is inserted within the female outer housing. The female outer housing receives a header having side walls surrounding mating electrical terminals. The locking arms define ramp features on outer sides of the locking arms that push the locking arms inwardly when the side walls contact the ramp features of the locking arms as the header is inserted within the outer housing. A method of assembling such an electrical connector is also provided.

Abstract: An electrical connector assembly includes a central electrical terminal connected to a cable terminal attached to an end of a central conductor of an electrical cable configured to mate with a corresponding mating central electrical terminal. The central electrical terminal comprises a helical coil spring in compressive contact with the cable terminal. The assembly also includes an insulative housing defining a cavity in which the central electrical terminal is affixed and a shield terminal in which the insulative housing, central electrical terminal, and coil spring are disposed. The insulative housing is configured to move longitudinally within the shield terminal. The coil spring exerts a longitudinal force on the central electrical terminal and the insulative housing to maintain mechanical contact between the insulative housing and a corresponding insulative housing in which the corresponding mating central electrical terminal is disposed.

Abstract: An electrical connector assembly includes an electrical receptacle terminal configured to receive a corresponding electrical plug terminal therein. The electrical receptacle terminal has a helical coil spring. The electrical connector assembly further includes a cable terminal attached to an end of a conductor of an electrical cable. The coil spring is in compressive contact with the cable terminal.

Abstract: A wire assembly includes a cable and a contact. The wire includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a tip of the inner conductor is exposed at a first end. The contact is welded to the tip of the inner conductor at the first end.

Abstract: An electrical connector is presented herein. The electrical connector includes an insulator that is formed of a dielectric material and defines a cavity extending therethrough. The cavity has a plurality of cylindrical sections. A first cylindrical section of the plurality of cylindrical sections has a diameter that is larger than a diameter of adjoining second and third cylindrical sections of the plurality of cylindrical sections on each side of the first cylindrical section. The insulator is preferably formed using an additive manufacturing process, such as stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, laminated object manufacturing, or 3D printing.

Abstract: A wire assembly includes a cable and a contact. The wire includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a tip of the inner conductor is exposed at a first end. The contact is welded to the tip of the inner conductor at the first end.

Abstract: A shielding electrical terminal is presented herein. The shielding electrical terminal includes a securing portion that is configured to attach to an outer shield conductor of a shielded cable and a cylindrical mating portion having an inner surface configured to make electrical contact with a corresponding cylindrical shield terminal inserted within the mating portion. The inner surface of the mating portion defines a plurality of protrusions that extend from the inner surface.

Abstract: A wire assembly includes a cable and a contact. The wire includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a tip of the inner conductor is exposed at a first end. The contact is welded to the tip of the inner conductor at the first end.

Abstract: An electrical connector is presented herein. The electrical connector includes an insulator that is formed of a dielectric material and defines a cavity extending therethrough. The cavity has a plurality of cylindrical sections. A first cylindrical section of the plurality of cylindrical sections has a diameter that is larger than a diameter of adjoining second and third cylindrical sections of the plurality of cylindrical sections on each side of the first cylindrical section. The insulator is preferably formed using an additive manufacturing process, such as stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, laminated object manufacturing, or 3D printing.

Abstract: A shielding electrical terminal is presented herein. The shielding electrical terminal includes a securing portion that is configured to attach to an outer shield conductor of a shielded cable and a cylindrical mating portion having an inner surface configured to make electrical contact with a corresponding cylindrical shield terminal inserted within the mating portion. The inner surface of the mating portion defines a plurality of protrusions that extend from the inner surface.

Abstract: An electrical connector includes a terminal having a first surface defining a plurality of ridges protruding from the first surface. A first ridge in the plurality of ridges has a different height above the first surface than a second ridge in the plurality of ridges. The plurality of ridges is configured to provide a plurality of electrical contact points between the terminal and a corresponding mating terminal. A method of manufacturing the electrical connector includes the steps of providing a terminal preform formed of sheet metal having the first surface and forming the plurality of ridges which protrude from the first surface.

Abstract: An electromagnetic terminal shield includes a shield body formed of sheet metal having a connector opening configured to receive a corresponding mating terminal shield and a cable opening configured to receive a wire cable and a plurality of cantilevered spring arms integrally formed with the shield body having fixed ends attached to the connector opening and free ends disposed within a shield cavity defined by the shield body. Each spring arm in the plurality of cantilevered spring arms has a free end that is in contact with the inner surface of the shield body within the shield cavity. A process for manufacturing an electromagnetic terminal shield and the electromagnetic terminal shield produced by this process are also presented herein.

Abstract: An electrical connector includes a terminal having a first surface defining a plurality of ridges protruding from the first surface. A first ridge in the plurality of ridges has a different height above the first surface than a second ridge in the plurality of ridges. The plurality of ridges is configured to provide a plurality of electrical contact points between the terminal and a corresponding mating terminal. A method of manufacturing the electrical connector includes the steps of providing a terminal preform formed of sheet metal having the first surface and forming the plurality of ridges which protrude from the first surface.

Abstract: An electromagnetic terminal shield includes a shield body formed of sheet metal having a connector opening configured to receive a corresponding mating terminal shield and a cable opening configured to receive a wire cable and a plurality of cantilevered spring arms integrally formed with the shield body having fixed ends attached to the connector opening and free ends disposed within a shield cavity defined by the shield body. Each spring arm in the plurality of cantilevered spring arms has a free end that is in contact with the inner surface of the shield body within the shield cavity. A process for manufacturing an electromagnetic terminal shield and the electromagnetic terminal shield produced by this process are also presented herein.

Abstract: An electromagnetic terminal shield includes a shield body formed of sheet metal having a connector opening configured to receive a corresponding mating terminal shield and a cable opening configured to receive a wire cable. The terminal shield also includes a plurality of cantilevered spring arms integrally formed with the shield body having fixed ends attached to the connector opening and free ends disposed within a shield cavity defined by the shield body. A process for manufacturing the electromagnetic terminal shield is also presented.

Abstract: An electrical connector assembly includes a dielectric connector housing having a cavity extending longitudinally therethrough and a shield terminal disposed within the cavity. The shield terminal has an attachment portion configured to receive a shield conductor of a coaxial cable and a connection portion configured to receive a cylindrical mating shield terminal. The connection portion defines a first cylindrical sector and a second cylindrical sector arranged opposite one another. The connection portion and the cavity cooperate to put the first and second cylindrical sectors in intimate contact with, and apply a compressive force to, the mating shield terminal when the mating shield terminal is inserted within the connection portion.

Abstract: A method of securing an electrical terminal within a terminal cavity of a connector body is described herein. The method includes the step of deforming a portion of an outer surface of the connector body to fabricate a protrusion that projects from an inner surface of the connector body into the terminal cavity, thereby securing the electrical terminal within the terminal cavity. A connector assembly formed by this method is also described.

Abstract: An electrical connector assembly includes an electrical terminal having an attachment end and a connection end, a first terminal housing having a first cavity in which the attachment end is disposed. The first cavity defining a terminal extension opening through which the connection end extends. The assembly also includes a second terminal housing having a second cavity in which the connection end is disposed. The second cavity defining a terminal reception opening through which the connection end is received. The first terminal housing defines a first attachment surface surrounding the terminal extension opening and the second terminal housing defines a second attachment surface surrounding the terminal reception opening. The first attachment surface is sealed to the second attachment surface. The first attachment surface forms a first angle relative to the longitudinal axis and the second attachment surface forms a second angle relative to the lateral axis.

Abstract: An electrical connector assembly includes a connector body and an electrical component having wire leads extending axially from each end of the body, and electrical terminals. The wire leads are connected to the terminals. The assembly further includes a retainer housing disposed within the connector body. The retainer housing defines a pair of longitudinal channels in which the terminals are disposed. The retainer housing defies a cradle having an arcuate cross section in which the electrical component is disposed. The retainer housing defines a retaining feature configured to retain the electrical component within the cradle.