EP3480900A1 - Stromanschlusssystem für abgeschirmtes drahtkabel - Google Patents

Stromanschlusssystem für abgeschirmtes drahtkabel Download PDF

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Publication number
EP3480900A1
EP3480900A1 EP18201302.9A EP18201302A EP3480900A1 EP 3480900 A1 EP3480900 A1 EP 3480900A1 EP 18201302 A EP18201302 A EP 18201302A EP 3480900 A1 EP3480900 A1 EP 3480900A1
Authority
EP
European Patent Office
Prior art keywords
shield
plug
receptacle
pair
crimp wings
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP18201302.9A
Other languages
English (en)
French (fr)
Inventor
Richard J BOYER
Klara P CARBONE
Leslie L JONES
Nicole L. Liptak
Dominic A MESSURI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Aptiv Technologies Ltd
Original Assignee
Aptiv Technologies Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US15/804,444 external-priority patent/US10211546B2/en
Application filed by Aptiv Technologies Ltd filed Critical Aptiv Technologies Ltd
Publication of EP3480900A1 publication Critical patent/EP3480900A1/de
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/22—Contacts for co-operating by abutting
    • H01R13/24—Contacts for co-operating by abutting resilient; resiliently-mounted
    • H01R13/2442—Contacts for co-operating by abutting resilient; resiliently-mounted with a single cantilevered beam
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
    • H01R13/6592—Specific features or arrangements of connection of shield to conductive members the conductive member being a shielded cable
    • H01R13/6593—Specific features or arrangements of connection of shield to conductive members the conductive member being a shielded cable the shield being composed of different pieces
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/002—Pair constructions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/02—Cables with twisted pairs or quads
    • H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
    • H01B11/10—Screens specially adapted for reducing interference from external sources
    • H01B11/1091—Screens specially adapted for reducing interference from external sources with screen grounding means, e.g. drain wires
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1875—Multi-layer sheaths
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6581—Shield structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/646—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00 specially adapted for high-frequency, e.g. structures providing an impedance match or phase match
    • H01R13/6473—Impedance matching
    • H01R13/6474—Impedance matching by variation of conductive properties, e.g. by dimension variations
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/648—Protective earth or shield arrangements on coupling devices, e.g. anti-static shielding  
    • H01R13/658—High frequency shielding arrangements, e.g. against EMI [Electro-Magnetic Interference] or EMP [Electro-Magnetic Pulse]
    • H01R13/6591—Specific features or arrangements of connection of shield to conductive members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2107/00—Four or more poles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/60—Contacts spaced along planar side wall transverse to longitudinal axis of engagement
    • H01R24/62—Sliding engagements with one side only, e.g. modular jack coupling devices

Definitions

  • the invention generally relates to an electrical connection system, and more particularly relates to an electrical connection system designed to connect shielded wire cables capable of differentially transmitting digital electrical signals having a data transfer rate of 5 Gigabits per second (Gb/s) or higher further requiring frequency content to 7.5 Gigahertz (GHz).
  • Gb/s Gigabits per second
  • GHz 7.5 Gigahertz
  • Transmission media used to connect electronic components to the digital data processors must be constructed to efficiently transmit the high speed digital signals between the various components.
  • Wired media such as fiber optic cable, coaxial cable, or twisted pair cable may be suitable in applications where the components being connected are in fixed locations and are relatively close proximity, e.g. separated by less than 100 meters.
  • Fiber optic cable provides a transmission medium that can support data rates of up to nearly 100 Gb/s and is practically immune to electromagnetic interference.
  • Coaxial cable typically supports data transfer rates up to 100 Megabits per second (Mb/s) and has good immunity to electromagnetic interference.
  • Twisted pair cable can support data rates of up to about 5 Gb/s, although these cables typically require multiple twisted pairs within the cable dedicated to transmit or receive lines.
  • the conductors of the twisted pair cables offer good resistance to electromagnetic interference which can be improved by including shielding for the twisted pairs within the cable.
  • USB Universal Serial Bus
  • HDMI High Definition Multimedia Interface
  • fiber optic and twisted pair cables are capable of transmitting data at these transfer rates, however fiber optic cables are significantly more expensive than twisted pair, making them less attractive for cost sensitive applications that do not require the high data transfer rates and electromagnetic interference immunity.
  • Infotainment systems and other electronic systems in automobiles and trucks are beginning to require cables capable of carrying high data rate signals.
  • Automotive grade cables must not only be able to meet environmental requirements (e.g. thermal and moisture resistance), they must also be flexible enough to be routed in a vehicle wiring harness and have a low mass to help meet vehicle fuel economy requirements. Therefore, there is a need for a wire cable with a high data transfer rate that has low mass and is flexible enough to be packaged within a vehicle wiring harness, while meeting cost targets that cannot currently be met by fiber optic cable.
  • this wire cable is automotive, such a wire cable would also likely find other applications, such as aerospace, maritime, industrial control, or other data communications.
  • an electrical connection system in accordance with one embodiment of this invention, includes a first shielded cable having a first electrical conductor and a second electrical conductor surrounded by a first shield conductor which is surrounded by a first insulating jacket, a second shielded cable having a third electrical conductor and a fourth electrical conductor surrounded by a second shield conductor which is surrounded by a second insulating jacket, a plug connector having a first plug terminal a second plug terminal, and a receptacle connector configured to mate with said plug connector having a first receptacle terminal and a second receptacle terminal configured to receive the first and second plug terminals respectively.
  • the electrical connection system further includes a plug shield longitudinally surrounding the plug connector and electrically isolated from the plug terminals having an upper plug shield and a lower plug shield.
  • the lower plug shield is attached to the first shield conductor by a first pair of shield crimp wings. An extremity of the first pair of shield crimp wings is collocated with an extremity of the first shield conductor.
  • the electrical connection system additionally includes a receptacle shield longitudinally surrounding the receptacle connector and electrically isolated from the receptacle terminals having an upper receptacle shield and a lower receptacle shield.
  • the lower receptacle shield is attached to the second shield conductor by a second pair of shield crimp wings. An extremity of the second pair of shield crimp wings is collocated with an extremity of the second shield conductor.
  • the extremity of the first pair of shield crimp wings may be in a range of 1.0 to 1.5 millimeters from the first and second attachment points and the extremity of the second pair of shield crimp wings may be in a range of 1.0 to 1.5 millimeters from the third and fourth attachment points.
  • the lower plug shield may be attached to the first insulating jacket by a first pair of jacket crimp wings and the lower plug shield may be attached to the upper plug shield by a first shield attaching feature located intermediate the first pair of shield crimp wings and the first pair of jacket crimp wings.
  • the lower receptacle shield may be attached to the second insulating jacket by a second pair of jacket crimp wings and the lower receptacle shield may be attached to the upper receptacle shield by a second shield attaching feature located intermediate the second pair of shield crimp wings and the second pair of shield crimp wings.
  • the upper plug shield may define a first tab in direct and compressive contact with the first pair of shield crimp wings of the lower plug shield and the upper receptacle shield may defines a second tab in direct and compressive contact with the second pair of shield crimp wings of the lower receptacle shield.
  • the upper plug shield may define a first pair of opposed tabs in direct and compressive contact with the first pair of shield crimp wings of the lower plug shield and the upper receptacle shield may define a second pair of opposed tabs in direct and compressive contact with the second pair of shield crimp wings of the lower receptacle shield.
  • the receptacle shield may be configured to slideably engage the interior of the plug shield.
  • the extremity of the first pair of shield crimp wings may be substantially flush with the extremity of the first shield conductor and the extremity of the second pair of shield crimp wings may be substantially flush with the extremity of the second shield conductor
  • the first plug terminal may include a planar first connection portion that is characterized by a generally rectangular cross section and a first attachment portion attached to the first electrical conductor.
  • the second plug terminal may also include a planar second connection portion that is characterized by a generally rectangular cross section and a second attachment portion attached to the second electrical conductor.
  • the first and second plug terminals may form a first mirrored terminal pair having bilateral symmetry about a longitudinal axis.
  • the first receptacle terminal may include a third attachment portion attached to the third electrical conductor and a first cantilever beam portion that is characterized by a generally rectangular cross section defining a convex first contact point depending from the first cantilever beam portion. The first contact point is configured to contact the first connection portion of the first plug terminal.
  • the second receptacle terminal may include a fourth attachment portion attached to the fourth electrical conductor and have a second cantilever beam portion that is characterized by a generally rectangular cross section defining a convex second contact point depending from the second cantilever beam portion.
  • the second contact point is configured to contact the second connection portion of the second plug terminal.
  • the first and second receptacle terminals may form a second mirrored terminal pair having bilateral symmetry about the longitudinal axis.
  • the wire cable assembly includes a wire cable having a pair of conductors (wire pair) and a conductive sheet and braided conductor to isolate the wire pair from electromagnetic interference and determine the characteristic impedance of the cable.
  • the wire pair is encased within dielectric belting that helps to provide a consistent radial distance between the wire pair and the shield. The belting may also help to maintain a consistent twist angle between the wire pair if they are twisted.
  • the consistent radial distance between the wire pair and the shield and the consistent twist angle provides a wire cable with more consistent impedance.
  • the wire cable assembly may also include an electrical receptacle connector having a mirrored pair of plug terminals connected to the wire pair and/or an electrical plug connector having a mirrored pair of receptacle terminals connected to the wire pair that is configured to mate with the plug terminals of the plug connector.
  • the receptacle and plug terminals each have a generally rectangular cross section and when the first and second electrical connectors are mated, the major widths of the receptacle terminals are substantially perpendicular to the major widths of the plug terminals and the contact points between the receptacle and plug terminals are external to the receptacle and plug terminals.
  • Both the receptacle and plug connectors include a shield that longitudinally surrounds the receptacle or plug terminals and is connected to the braided conductor of the wire cable.
  • the wire cable assembly may also include an insulative connector body that contains the receptacle or plug terminals and shield.
  • Figs. 1 and 2 illustrate a non-limiting example of a wire cable 100 used in the wire cable assembly.
  • the wire cable 100 includes a central pair of conductors comprising a first inner conductor, hereinafter referred to as the first conductor 102 and a second inner conductor, hereinafter referred to as the second conductor 104.
  • the first and second conductors 102, 104 are formed of a conductive material with superior conductivity, such as unplated copper or silver plated copper.
  • copper refers to elemental copper or a copper-based alloy.
  • silver refers to elemental silver or a silver-based alloy.
  • the design, construction, and sources of copper and silver plated copper conductors are well known to those skilled in the art.
  • the first and second conductors 102, 104 each comprise a solid wire conductor, such as a bare (non-plated) copper wire or silver plated copper wire having a diameter of about 0.321 millimeters (mm), which is generally equivalent to 28 AWG solid wire.
  • the first and second conductors 102, 104 may be formed of a solid wire having a smaller gauge, such as 30 AWG or 32 AWG.
  • Alternative embodiments of the wire cable may use stranded wire for the first and second conductors 102, 104.
  • the central pair of first and second conductors 102, 104 may be longitudinally twisted over a lay length L, for example once every 15.24 mm. Twisting the first and second conductors 102, 104 provides the benefit of reducing low frequency electromagnetic interference of the signal carried by the central pair. However, the inventors have discovered that satisfactory signal transmission performance may also be provided by a wire cable wherein the first and second conductors 102, 104 are not twisted about one about the other. Not twisting the first and second conductors 102, 104 may provide the benefit of reducing manufacturing cost of the wire cable by eliminating the twisting process. Not twisting the first and second conductors 102, 104 results in reduced differential insertion loss but has the disadvantage of requiring specific limitations in vehicle routing, specifically to non-uniform bending along the length of the cable run.
  • first and second conductors 102, 104 are enclosed within a respective first dielectric insulator and a second dielectric insulator, hereafter referred to as the first and second insulators 108, 110.
  • the first and second insulators 108, 110 are bonded together.
  • the first and second insulators 108, 110 run the entire length of the wire cable 100, except for portions that are removed at the extremities of the cable in order to terminate the wire cable 100.
  • the first and second insulators 108, 110 are formed of a flexible dielectric material, such as polypropylene.
  • the first and second insulators 108, 110 may be characterized as having a thickness of about 0.85 mm.
  • Bonding the first insulator 108 to the second insulators 110 helps to maintain a consistent spacing S between the first and second conductors 102, 104.
  • the methods required to manufacture a pair of conductors with bonded insulators are well known to those skilled in the art.
  • the first and second conductors 102, 104 and the first and second insulators 108, 110 are completely enclosed within a third dielectric insulator, hereafter referred to as the belting 112, except for portions that are removed at the extremities of the cable in order to terminate the wire cable 100.
  • the first and second insulators 108, 110 and the belting 112 together form a dielectric structure 113.
  • the belting 112 is formed of a flexible dielectric material, such as polyethylene. As illustrated in Fig. 2 , the belting may be characterized as having a diameter D of 2.22 mm.
  • a release agent 114 such as a talc-based powder, may be applied to an outer surface of the bonded first and second insulators 108, 110 in order to facilitate removal of the belting 112 from the first and second insulators 108, 110 when ends of the first and second insulators 108, 110 are stripped from the first and second conductors 102, 104 to form terminations of the wire cable 100.
  • the belting 112 is completely enclosed within a conductive sheet, hereafter referred to as the inner shield 116, except for portions that may be removed at the extremities of the cable in order to terminate the wire cable 100.
  • the inner shield 116 is longitudinally wrapped in a single layer about the belting 112, so that it forms a single seam 118 that runs generally parallel to the central pair of first and second conductors 102, 104.
  • the inner shield 116 is not spirally wrapped or helically wrapped about the belting 112.
  • the seam edges of the inner shield 116 may overlap, so that the inner shield 116 covers at least 100 percent of an outer surface of the belting 112.
  • the inner shield 116 is formed of a flexible conductive material, such as aluminized biaxially oriented PET film.
  • Biaxially oriented polyethylene terephthalate film is commonly known by the trade name MYLAR and the aluminized biaxially oriented PET film will hereafter be referred to as aluminized MYLAR film.
  • the aluminized MYLAR film has a conductive aluminum coating applied to only one of the major surfaces; the other major surface is non-aluminized and therefore non-conductive.
  • the design, construction, and sources for single-sided aluminized MYLAR films are well known to those skilled in the art.
  • the non-aluminized surface of the inner shield 116 is in contact with an outer surface of the belting 112.
  • the inner shield 116 may be characterized as having a thickness of less than or equal to 0.04 mm.
  • the belting 112 provides the advantage of maintaining transmission line characteristics and providing a consistent radial distance between the first and second conductor 102, 104 and the inner shield 116.
  • the belting 112 further provides an advantage of keeping the twist lay length between the first and second conductors 102, 104 consistent. Shielded twisted pair cables found in the prior art typically only have air as a dielectric between the twisted pair and the shield. Both the distance between first and second conductors 102, 104 and the inner shield 116 and the effective twist lay length of the first and second conductors 102, 104 affect the wire cable impedance. Therefore a wire cable with more consistent radial distance between the first and second conductors 102, 104 and the inner shield 116 provides more consistent impedance. A consistent twist lay length of the first and second conductors 102, 104 also provides controlled impedance.
  • a wire cable may be envisioned incorporating a single dielectric structure encasing the first and second insulators to maintain a consistent lateral distance between the first and second insulators and a consistent radial distance between the first and second insulators and the inner shield.
  • the dielectric structure may also keep the twist lay length of the first and second conductors consistent.
  • the wire cable 100 additionally includes a ground conductor, hereafter referred to as the drain wire 120 that is disposed outside of the inner shield 116.
  • the drain wire 120 extends generally parallel to the first and second conductors 102, 104 and is in intimate contact or at least in electrical communication with the aluminized outer surface of the inner shield 116.
  • the drain wire 120 comprises a solid wire conductor, such as an unplated copper conductor, tin plated copper conductor, or silver plated copper conductor having a cross section of about 0.321 mm 2 , which is generally equivalent to 28 AWG solid wire.
  • the drain wire 120 may be formed of solid wire having a smaller gauge, such as 30 AWG or 32 AWG.
  • Alternative embodiments of the wire cable may use stranded wire for the drain wire 120.
  • the design, construction, and sources of copper and tin plated copper conductors are well known to those skilled in the art.
  • the wire cable 100 further includes a braided wire conductor, hereafter referred to as the outer shield 124, enclosing the inner shield 116 and the drain wire 120, except for portions that may be removed at the ends of the cable in order to terminate the wire cable 100.
  • the outer shield 124 is formed of a plurality of woven conductors, such as copper or tin plated copper. As used herein, tin refers to elemental tin or a tin-based alloy. The design, construction, and sources of braided conductors used to provide such an outer shield are well known to those skilled in the art.
  • the outer shield 124 is in intimate contact or at least in electrical communication with both the inner shield 116 and the drain wire 120.
  • the wires forming the outer shield 124 may be in contact with at least 65 percent of an outer surface of the inner shield 116.
  • the outer shield 124 may be characterized as having a thickness less than or equal to 0.30 mm.
  • the wire cable 100 shown in Figs. 1 and 2 further includes an outer dielectric insulator, hereafter referred to as the jacket 126.
  • the jacket 126 encloses the outer shield 124, except for portions that may be removed at the extremities of the cable in order to terminate the wire cable 100.
  • the jacket 126 forms an outer insulation layer that provides both electrical insulation and environmental protection for the wire cable 100.
  • the jacket 126 is formed of a flexible dielectric material, such as polyvinyl chloride (PVC).
  • PVC polyvinyl chloride
  • the jacket 126 may be characterized as having a thickness of about 0.2 mm.
  • the wire cable 100 is constructed so that the inner shield 116 is tight to the belting 112, the outer shield 124 is tight to the drain wire 120 and the inner shield 116, and the jacket 126 is tight to the outer shield 124 so that the formation of air gaps between these elements is minimized or compacted. This provides the wire cable 100 with controlled magnetic permeability.
  • the wire cable 100 may be characterized as having a differential impedance of 95 Ohms.
  • Fig. 3 illustrates the requirements for signal rise time (in picoseconds (ps)) and differential impedance (in Ohms ( ⁇ )) for the USB 3.0 and HDMI 1.4 performance specifications.
  • Fig. 3 also illustrates the combined requirements for a wire cable capable of simultaneously meeting both USB 3.0 and HDMI 1.4 standards. The wire cable is expected to meet the combined USB 3.0 and HDMI 1.4 signal rise time and differential impedance requirements shown in Fig. 7 .
  • Fig. 4 illustrates the differential impedances that are expected for the wire cables 100 over a signal frequency range of 0 to 7500 MHz (7.5 GHz).
  • Fig. 5 illustrates the insertion losses that are expected for wire cable 100 with a length of 7 m over the signal frequency range of 0 to 7500 MHz (7.5 GHz).
  • the wire cable 100 having a length of up to 7 meters are expected to be capable of transmitting non return to zero (NRZ) digital data at a speed of up to 5 Gigabits per second with an insertion loss of less than 20 dB.
  • NRZ non return to zero
  • the wire cable assembly includes an electrical connector assembly.
  • the connector assembly includes a receptacle connector 128 and a plug connector 130 configured to accept the receptacle connector 128 as illustrated in Fig. 7 .
  • the receptacle connector 128 include two terminals, a first receptacle terminal 132 connected to a first inner conductor 102 and a second receptacle terminal 134 connected to a second inner conductor (not shown due to drawing perspective) of the wire cable 100.
  • the first receptacle terminal 132 includes a first cantilever beam portion 136 that has a generally rectangular cross section and defines a convex first contact point 138 that depends from the first cantilever beam portion 136 near the free end of the first cantilever beam portion 136.
  • the second receptacle terminal 134 also includes a similar second cantilever beam portion 140 having a generally rectangular cross section and defining a convex second contact point 142 depending from the second cantilever beam portion 140 near the free end of the second cantilever beam portion 140.
  • the first and second receptacle terminals 132, 134 each comprise an attachment portion 144 that is configured to receive the end of an inner conductor of the wire cable 100 and provide a surface for attaching the first and second inner conductors 102, 104 to the first and second receptacle terminals 132, 134.
  • the attachment portions 144 are configured to maintain the consistent spacing S between the first and second inner conductors 102, 104.
  • the outer shield 124 of the shielded cable 100 extends close to the attachment portion 144.
  • a receptacle terminal holder 148 partially encases the first and second receptacle terminal 132, 134.
  • the receptacle terminal holder 148 maintains the spatial relationship between the first and second receptacle terminals 132, 134 to maintain the consistent spacing S between the first and second inner conductors 102, 104.
  • the first and second receptacle terminals 132, 134 form a mirrored terminal pair that has bilateral symmetry about the longitudinal axis X and are substantially parallel to the longitudinal axis X and each other.
  • the distance between the first cantilever beam portion 136 and the second cantilever beam portion 140 is 2.85 mm, center to center.
  • the first and second inner conductors 102, 104 of the wire cable 100 are attached to the attachment portions 144 of the first and second receptacle terminals 132, 134 using an ultrasonic welding process.
  • the plug connector 130 includes two terminals, a first plug terminal 160 connected to a first inner conductor 102 and a second plug terminal 162 connected to a second inner conductor 104 of the wire cable 100.
  • the first plug terminal 160 includes a first elongate planar portion 164 that has a generally rectangular cross section.
  • the second plug terminal 162 also includes a similar second elongate planar portion 166.
  • the planar portions of the plug terminals 160, 162 are configured to receive and contact the first and second contact points 138, 142 of the first and second receptacle terminals 132, 134.
  • the free ends of the planar portions have a beveled shape to allow the mating first and second receptacle terminals 132, 134 to ride up and over free ends of the first and second planar portions 164, 166 when the plug connector 130 and receptacle connector 128 are mated.
  • the first and second plug terminals 160, 162 each comprise an attachment portion 144 similar to the attachment portions 144 of the first and second receptacle terminals 132, 134 that are configured to receive the ends of the first and second inner conductors 102, 104 and provide a surface for attaching the first and second inner conductors 102, 104 to the first and second plug terminals 160, 162.
  • the attachment portions 144 are configured to maintain the consistent spacing between the first and second inner conductors 102, 104.
  • the outer shield 124 of the shielded cable 100 extends close to the attachment portion 144.
  • a plug terminal holder 170 partially encases the first and second plug terminals 160, 162.
  • the plug terminal holder 170 maintains the spatial relationship between the first and second plug terminals 160, 162 to maintain the consistent spacing S between the first and second inner conductors 102, 104.
  • the first and second plug terminals 160, 162 form a mirrored terminal pair that has bilateral symmetry about the longitudinal axis X and are substantially parallel to the longitudinal axis X and each other.
  • the distance between the first planar portion and the second planar portion is 2.85 mm, center to center.
  • the inventors have observed through data obtained from computer simulation that the mirrored parallel receptacle terminals 132, 134 and plug terminals 160, 162 have a strong effect on the high speed electrical properties, such as impedance and insertion loss, of the wire cable assembly.
  • the first and second inner conductors 102, 104 of the wire cable 100 are attached to the attachment portions 144 of the first and second plug terminals 160, 162 using an ultrasonic welding process.
  • the first and second plug terminals 160, 162 and the first and second receptacle terminals 132, 134 are oriented in the plug and receptacle connectors 128, 130 so that when the plug and receptacle connectors 128, 130 are mated, the major widths of the first and second receptacle terminals 132, 134 are substantially perpendicular to the major widths of the first and second plug terminals 160, 162.
  • substantially perpendicular means that the major widths are ⁇ 15° of absolutely perpendicular. The inventors have observed that this orientation between the first and second plug terminals 160, 162 and the first and second receptacle terminals 132, 134 has strong effect on insertion loss.
  • the first and second receptacle terminals 132, 134 overlap the first and second plug terminals 160, 162.
  • the plug and receptacle connectors 128, 130 are configured so that only the first and second contact points 138, 142 of the first and second receptacle terminals 132, 134 contacts the planar blade portion of the first and second plug terminals 160, 162 and the contact area defined between the first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 is less than the area overlapped between the first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162.
  • the contact area is determined by the area of the first and second contact points 138, 142 and not by the overlap between the terminals. Therefore, the receptacle terminals 132, 134 and the plug terminals 160, 162 provide the benefit of providing a consistent contact area as long as the first and second contact points 138, 142 of the first and second receptacle terminals 132, 134 are fully engaged with the first and second plug terminals 160, 162. Because both the plug and receptacle terminals are a mirrored pair, a first contact area between the first receptacle terminal 132 and the first plug terminal 160 and a second contact area between the second receptacle terminal 134 and the second plug terminal 162 are substantially equal.
  • substantially equal means that the contact area difference between the first contact area and the second contact area is less than 0.1 mm 2 .
  • the inventors have observed through data obtained from computer simulation that the contact area between the plug and receptacle terminals and the difference between the first contact are a and the second contact area have a strong impact on insertion loss of the wire cable assembly.
  • the first and second plug terminals 160, 162 are not received within the first and second receptacle terminals 132, 134, therefore the first contact area is on the exterior of the first plug terminal 160 and the second contact area is on the exterior of the second plug terminal 162 when the plug connector 130 is mated to the receptacle connector 128.
  • the first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 may be formed from a sheet of copper-based material.
  • the first and second cantilever beam portions 136, 140 and the first and second planar portions 164, 166 may be selectively plated using copper/nickel/silver based plating.
  • the terminals may be plated to a 5 skin thickness.
  • the first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 are configured so that the receptacle connector 128 and plug connector 130 exhibit a low insertion normal force of about 0.4 Newton (45 grams). The low normal force provides the benefit of reducing abrasion of the plating during connection/disconnection cycles.
  • the plug connector 130 includes a plug shield 172 that is attached to the outer shield 124 of the wire cable 100.
  • the plug shield 172 is separated from and longitudinally surrounds the first and second plug terminals 160, 162 and plug terminal holder 170.
  • the receptacle connector 128 also includes a receptacle shield 174 that is attached to the outer shield 124 of the wire cable 100 that is separated from and longitudinally surrounds the first and second receptacle terminals 132, 134, receptacle terminal holder 148 and receptacle terminal cover 152.
  • the receptacle shield 174 and the plug shield 172 are configured to slidingly contact one another and when mated, to provide electrical continuity between the outer shields 124 of the attached wire cables 100 and to provide electromagnetic shielding to the plug and receptacle connectors 128, 130.
  • the plug shield 172 is made of two parts, a lower plug shield 172A and a upper plug shield 172B.
  • the lower plug shield 172A includes two pairs of crimping wings: shield crimp wings 176 adjacent an attachment portion of the lower plug shield 172A that is configured to receive the exposed end of the outer shield 124 of the wire cable 100 and jacket crimp wings 178.
  • the shield crimp wings 176 are bypass-type crimp wings that are offset and configured to surround the exposed end of the outer shield 124 of the wire cable 100 when the shield crimp wings 176 are crimped to the wire cable 110.
  • an extreme end i.e.
  • the extremity, of the shield crimp wings 176 is disposed on an extreme end, i.e. extremity, of the outer shield 124.
  • the extremity of the shield crimp wings 176 is within 1.0 to 1.5 mm of the attachment of the first and second conductors 102, 104 to the attachment portions 144 of the plug terminals 160, 162.
  • the drain wire 120 is electrically coupled to the lower plug shield 172A when the lower plug shield 172A is crimped to the outer shield 124 because the drain wire 120 of the wire cable 100 is sandwiched between the outer shield 124 and the inner shield 116 of the wire cable 110.
  • the jacket crimp wings 178 are also bypass type wings that are offset and configured to surround the jacket 126 of the wire cable 100 when the lower plug shield 172A is crimped to the wire cable 110.
  • the upper plug shield 172B includes a pair of flexible tabs 146 located opposite one another that are positioned to directly contact the shield crimp wings 176 and apply a compressive force to the shield crimp wings 176.
  • These flexible tabs 146 provide improved electrical contact between the upper plug shield 172B and the outer shield 124 than is provided when the upper plug shield 172B is connected to the outer shield 124 only through the lower plug shield 172A.
  • the receptacle shield 174 is similarly made of two parts, a lower receptacle shield 174A and a upper receptacle shield 174B.
  • the lower receptacle shield 174A includes two pairs of crimping wings: shield crimp wings 176 adjacent an attachment portion of the lower receptacle shield 174A that is configured to receive the exposed end of the outer shield 124 of the wire cable 100 and jacket crimp wings 178.
  • the shield crimp wings 176 are bypass-type crimp wings that are offset and configured to surround the exposed end of the outer shield 124 of the wire cable 100 when the shield crimp wings 176 are crimped to the wire cable 110.
  • an extreme end, i.e. extremity, of the shield crimp wings 176 is disposed on an extreme end, i.e. extremity, of the outer shield 124.
  • the extremity of the shield crimp wings 176 is within 1.0 to 1.5 mm of the attachment of the first and second conductors 102, 104 to the attachment portions 144 of the receptacle terminals 132, 134.
  • the drain wire 120 is electrically coupled to the lower receptacle shield 174A when the lower receptacle shield 174A is crimped to the outer shield 124 because the drain wire 120 of the wire cable 100 is sandwiched between the outer shield 124 and the inner shield 116 of the wire cable 110.
  • the insulation crimp wings are also bypass type wings that are offset and configured to surround the jacket 126 of the wire cable 100 when the lower receptacle shield 174A is crimped to the wire cable 100.
  • the upper receptacle shield 174B similarly includes a pair of flexible tabs 146 located opposite one another that are positioned to directly contact the shield crimp wings 176 and apply a compressive force to the shield crimp wings 176.
  • These flexible tabs 146 provide improved electrical contact between the upper receptacle shield 174B and the outer shield 124 than is provided when the upper receptacle shield 174B is connected to the outer shield 124 only through the lower receptacle shield 174A.
  • the exterior of the plug shield 172 of the illustrated example is configured to slideably engage the interior of the receptacle shield 174
  • alternative embodiments may be envisioned wherein the exterior of the receptacle shield 174 slideably engages the interior of the plug shield 172.
  • the receptacle shield 174 and the plug shield 172 may be formed from a sheet of copper-based material.
  • the receptacle shield 174 and the plug shield 172 may be plated using copper/nickel/silver or tin based plating.
  • the first and upper receptacle shield 174A, 174B and the first and upper plug shield 172A, 172B may be formed by stamping processes well known to those skilled in the art.
  • plug connector 130 and receptacle connector 128 illustrated herein are connected to a wire cable, other embodiments of the plug connector and receptacle connector may be envisioned that are connected to conductive traces on a circuit board.
  • the wire cable assembly may further include a receptacle connector body 190 and a plug connector body 192 as illustrated in Fig. 6 .
  • the receptacle connector body 190 and the plug connector body 192 are formed of a dielectric material, such as a polyester material.
  • a connector assembly is provided.
  • the connector assembly is suited for terminating wire cables 100 and is capable of transmitting digital data signals with data rates of 3.5 Gb/s or higher without modulation or encoding.
  • the connector assembly provides the benefit of improved electromagnetic shielding of the plug terminals 160, 162 and receptacle terminals 132, 134 due to the decreased effective lengths of the plug shield 172 and receptacle shield 174 provided by the location of the shield crimp wings176 in close proximity to the attachment portions 144 of the terminals.
  • the connector assembly also provides the benefit of improved electrical connections between the upper plug and receptacle shields 172B, 174B and the outer shields 124 of the wire cables 100.

Landscapes

  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Insulated Conductors (AREA)
EP18201302.9A 2017-11-06 2018-10-18 Stromanschlusssystem für abgeschirmtes drahtkabel Withdrawn EP3480900A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US15/804,444 US10211546B2 (en) 2013-12-10 2017-11-06 Electrical connection system for shielded wire cable

Publications (1)

Publication Number Publication Date
EP3480900A1 true EP3480900A1 (de) 2019-05-08

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EP18201302.9A Withdrawn EP3480900A1 (de) 2017-11-06 2018-10-18 Stromanschlusssystem für abgeschirmtes drahtkabel

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EP (1) EP3480900A1 (de)
JP (1) JP6752260B2 (de)
KR (1) KR102091944B1 (de)
CN (1) CN109755816B (de)

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US11784482B2 (en) * 2020-10-20 2023-10-10 Apple Inc. Electrical connection monitoring using cable shielding
TWI752712B (zh) * 2020-11-04 2022-01-11 力生機械有限公司 高頻傳輸動態線及傳輸線組
DE102021117039A1 (de) 2021-07-01 2023-01-05 Te Connectivity Germany Gmbh Elektrische Mehradernkabel-Crimpferrule sowie Crimpverfahren

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JP2019106356A (ja) 2019-06-27
CN109755816B (zh) 2021-02-05
KR20190051826A (ko) 2019-05-15
CN109755816A (zh) 2019-05-14
KR102091944B1 (ko) 2020-03-23
JP6752260B2 (ja) 2020-09-09

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