WO2012003347A1 - Method of manufacturing a connector insert, connector insert and cable - Google Patents

Method of manufacturing a connector insert, connector insert and cable Download PDF

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Publication number
WO2012003347A1
WO2012003347A1 PCT/US2011/042634 US2011042634W WO2012003347A1 WO 2012003347 A1 WO2012003347 A1 WO 2012003347A1 US 2011042634 W US2011042634 W US 2011042634W WO 2012003347 A1 WO2012003347 A1 WO 2012003347A1
Authority
WO
WIPO (PCT)
Prior art keywords
cable
shield
insert
connector insert
wires
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.)
Ceased
Application number
PCT/US2011/042634
Other languages
English (en)
French (fr)
Inventor
Min Chul Kim
Paul Yuan
Josh Pong
Joseph Tang
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.)
Apple Inc
Original Assignee
Apple Inc
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
Application filed by Apple Inc filed Critical Apple Inc
Priority to BR112012031398A priority Critical patent/BR112012031398A2/pt
Priority to JP2012547345A priority patent/JP5342700B2/ja
Priority to EP11738523.7A priority patent/EP2589119B1/en
Priority to KR1020127032488A priority patent/KR101408474B1/ko
Publication of WO2012003347A1 publication Critical patent/WO2012003347A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

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
    • H01R13/648—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/51—Fixed connections for rigid printed circuits or like structures
    • H01R12/53—Fixed connections for rigid printed circuits or like structures connecting to cables except for flat or ribbon cables
    • 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
    • H01R13/6461—Means for preventing cross-talk
    • H01R13/6463—Means for preventing cross-talk using twisted pairs of wires
    • 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
    • H01R13/6461—Means for preventing cross-talk
    • H01R13/6471—Means for preventing cross-talk by special arrangement of ground and signal conductors, e.g. GSGS [Ground-Signal-Ground-Signal]
    • 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]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H01R4/023—Soldered or welded connections between cables or wires and terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0249—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for simultaneous welding or soldering of a plurality of wires to contact elements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/08—Cable junctions
    • 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
    • H01R13/65912—Specific features or arrangements of connection of shield to conductive members for shielded multiconductor cable
    • H01R13/65915—Twisted pair of conductors surrounded by shield
    • 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
    • H01R13/66—Structural association with built-in electrical component
    • H01R13/665—Structural association with built-in electrical component with built-in electronic circuit
    • H01R13/6658—Structural association with built-in electrical component with built-in electronic circuit on printed circuit board
    • 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
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49179—Assembling terminal to elongated conductor by metal fusion bonding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49174—Assembling terminal to elongated conductor
    • Y10T29/49181—Assembling terminal to elongated conductor by deforming
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/4921—Contact or terminal manufacturing by assembling plural parts with bonding
    • Y10T29/49211—Contact or terminal manufacturing by assembling plural parts with bonding of fused material
    • Y10T29/49213—Metal

Definitions

  • cables are needed. These cables may be active in that they include active electronic components, such as integrated circuits. These circuits consume power and thus create heat. This heat can degrade reliability of the cable and its circuitry, and can also be unpleasant for a user to touch.
  • the cable inserts may be able to transfer heat in a way to improve user experience and cable reliability.
  • the cables may have increased strength.
  • the cables and connector inserts may be arranged in such a way as to provide improved manufacturability.
  • embodiments of the present invention may provide high speed connector inserts and cables having improved heat conduction, high strength, and may be manufactured in a reliable manner.
  • An exemplary embodiment of the present invention may provide a connector insert having improved heat conduction.
  • This connector insert may include several paths by which heat may be removed from circuitry in the cable insert.
  • heat may be removed from one or more circuits by forming a thermal path between the circuit, which may be an integrated circuit or other device, and a shield of the connector insert.
  • This path may include a thermally conductive material to further reduce its thermal resistance.
  • Another example may include one or more pads on a side of an integrated circuit board. These pads may be soldered directly to the shield, or otherwise thermally connected to the shield.
  • braiding surrounding a cable may be soldered or otherwise thermally connected to the shield.
  • This connection may be covered by a cap to avoid electromagnet interference (EMI) leakage.
  • EMI electromagnet interference
  • This cap may be crimped to provide a robust mechanical connection. This crimping may be accomplished by applying force to the cap in multiple directions. In one specific embodiment of the present invention, force may be applied to the cap in four directions during crimping.
  • the cap may be soldered to portions of either or both the connector insert and cable for improved heat conduction and mechanical reliability.
  • a braiding surrounding the cable or one or more of its conductors may include one or more types of fibers.
  • aramid fibers may be included in the braiding around the cable.
  • the aramid or other fibers may be bunched or grouped, such that they may be pulled out of the way. In various embodiments of the present invention, these fibers may be pulled out of the way using static electricity, or by other mechanisms.
  • a specific embodiment of the present invention may use a braiding formed of counter-rotating spirals to assist in the separation of the aramid fibers.
  • Another exemplary embodiment of the present invention may provide for a reliable manufacturability.
  • One specific example may align several pairs of twisted pairs of conductors in the cable using a wire comb.
  • a wire comb having a plurality of openings may be used to hold twisted pairs in an aligned manner. This may allow soldering of the cables to a printed circuit board or other appropriate substrate. In various embodiments of the present invention, this soldering may be accomplished in a reliable manner using a solder bar.
  • Figure 1 illustrates a connector plug according to an embodiment of the present invention
  • Figure 2 illustrates a side view of a connection between a cable and a connector insert shield
  • Figure 3 illustrates a cap that may be located over solder locations joining a cable braiding and connector insert shield
  • Figure 4 illustrates a crimping technique that may be employed by embodiments of the present invention
  • Figure 5 is a cross-section of a high-speed cable according to an embodiment of the present invention.
  • Figure 6 is a more detailed view of a twisted pair according to an embodiment of the present invention.
  • Figure 7 illustrates a side view of a portion of the cable according to an embodiment of the present invention
  • Figure 8 illustrates the construction of a cable according to an embodiment of the present invention
  • Figure 9 illustrates a wire comb that may be used to align twisted-pairs emerging from a cable according to an embodiment of the present invention
  • Figure 10 illustrates a plurality of conductors that may be soldered to solder pads on a printed circuit board
  • Figure 1 1 illustrates a method of soldering conductors to a printed circuit board according to an embodiment of the present invention
  • Figure 12 illustrates a connector insert according to an embodiment of the present invention
  • Figure 13 illustrates an exploded view of a connector insert according to an
  • Figure 1 illustrates a side view of a connector plug according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims.
  • this plug may be part of an active cable for high-speed data communications.
  • it may include active circuitry, such as chip 140, which consumes power and generates heat. This heat can reduce the reliability of the active circuitry and make for an unpleasant user experience if it becomes excessively hot. Thus, it is desirable to remove heat from this connector plug. Accordingly, embodiments of the present invention may provide several low thermal resistance paths to dissipate this heat.
  • This connector plug includes plug connectors 1 10, which may mate with conductors of a connector receptacle (not shown). Plug connectors 1 10 may mechanically attach to printed circuit board 120. These plug connectors 1 10 may electrically connect to chip 140 using traces on printed circuit board 120. Plug connectors and chip 140 may connect to wires and cable 130 via traces on printed circuit board 120. Housing 170 may be used to surround shield 1 50.
  • Chip 140 may be an example circuit of many circuits that may generate the majority of heat in this plug. Again, embodiments of the present invention may employ several paths by which heat can be dissipated. In the first, heat can be removed from chip 140 directly to shield 150. Accordingly, a thermal conductor layer 160 may be used to provide a thermal path from chip 140 to shield 150. In a second path, chip 140 may attach to printed circuit board 120, thereby allowing heat to flow into printed circuit board 120. A solder area 1 80, which may be on the side, bottom, or top of printed circuit board 120, may be soldered to a portion of shield 150, thereby creating a low thermal resistance path from the printed circuit board to the shield for heat dissipation.
  • a side of the printed circuit board 120 is plated and soldered to the shield. The heat thus travels from the chip to the printed circuit board, then to the shield via the edge plating, then to the cable via cable braiding.
  • the cable (not shown) also provides a path for heat to leave this plug.
  • a braiding or other layer of the cable may be soldered or otherwise attached to shield 150. This may allow head to dissipate through the cable.
  • a low thermal path which may include liquid, metal, or other material, may be included in the cable.
  • Plug conductors 1 10 may also provide a heat path into a device receptacle.
  • the device receptacle may be designed to provide low thermal resistance paths to further aid in the dissipation of heat in the plug.
  • Figure 2 illustrates a side view of a connection between cable 230 and connector insert shield 250.
  • Cable braiding 234 may be pulled away from cable 230 and soldered to shield 250 at solder locations 236.
  • Conductors (not shown) in cable 230 may connect to circuitry inside shield 250.
  • Housing 270 may surround portion of shield 250 to provide thermal insulation and the location for a user to grasp the connector insert.
  • one or more openings 238 may form.
  • shield 250 may have a width greater than its height. Some or all of cable braiding 234 may attach to shield 250 along the width of shield 250, thereby leaving opening 238 along the height (or side) of shield 250. Opening 238 may provide a path for electromagnetic interference to be emitted from the cable conductors (not shown). Accordingly, embodiments of the present invention may employ a cap or other structure over the opening 238. An example is shown in the following figure.
  • Figure 3 illustrates a cap 339 that may be located over solder locations 236 between a cable braiding 234 and connector insert shield 250 consistent with embodiments of the present invention.
  • Cap 339 may be formed of metal such as aluminum, stainless steel, or other material.
  • cap 339 may be placed over solder locations 236 and crimped to be held in place. Cap 339 may also be soldered to provide additional shielding and mechanical support.
  • FIG. 4 illustrates a crimping technique employed by various embodiments of the present invention.
  • force is applied in four directions by tool die 410 on cap 439.
  • These forces may crimp cap 439 in a highly symmetrical manner for improved yield, improved EMI isolation, and mechanical stability.
  • this technique may reduce asymmetric forces that cable 330 would otherwise experience, thereby reducing the chance of damage to interior conductors (not shown) in cable 330 during manufacturing.
  • force may be applied to cap 439 in four directions, though in other embodiments of the present invention, force may be applied in other numbers of directions, such as two, three, or more than four directions.
  • embodiments of the present invention may provide a cable having a high strength.
  • a shield or braiding surrounding the cable or one or more of its conductors may include one or more types of fibers.
  • aramid fibers may be included in a shield or braiding around the cable.
  • aramid fibers may interfere with the soldering process outlined above.
  • the aramid or other fibers may be bunched or grouped in the cable shield or braiding, such that they may be pulled out of the way during soldering.
  • these fibers may be pulled out of the way using static electricity, or by other mechanisms.
  • An example of such a cable is shown in the following figure.
  • Figure 5 is a cross-section of a high-speed cable according to an embodiment of the present invention.
  • This cable may include four twisted pairs 520 and four single wires 530.
  • Twisted pairs 520 may be used to carry differential signals, multiple single ended signals, power, ground, bias, control, status, or other types of signal, power, status, or control lines.
  • Single wires 530 may be used to convey single ended signals, one side of a differential signal, power, ground, bias control, status, or other types of signal, power, status, or control lines.
  • cables consistent with embodiments of the present invention may include other numbers of twisted pairs and single wires.
  • twisted-pairs 520 and single wires 530 surround a nylon core 560, which is used for mechanical support.
  • nylon core 560 may be substituted by a wire, one or more fiber-optic lines, or other conductor or fiber. These connectors may be bound by shield tape 580.
  • Shield braid 540 may surround the cable.
  • Jacket 570 may surround shield braid 540 and provide mechanical support for the cable.
  • aramid fibers 550 may be dispersed or grouped in shield braid 540.
  • Shield braid 540 may be a conventional interwoven braiding, shield braid 540 may be formed of one or more counter-rotating spirals, or shield braiding 540 may be formed in other various ways.
  • FIG. 6 is a more detailed view of twisted pair 520 according to an embodiment of the present invention.
  • Twisted pairs 520 may include two conductors 610 surrounded by insulation layer 630.
  • Spiral shield 620 may surround twisted-pair 520 and provides shielding against electromagnetic interference.
  • Spiral shield 620 like shield braid 540, may be formed of braiding, one or more counter-rotating spirals, or other ways.
  • Copper Mylar tape layer 670 may bind and provide mechanical support for spiral shield 620 and conductors 610.
  • embodiments of the present invention may employ one, two, or more counter- rotating spirals as a shield.
  • An example is shown in the following figure.
  • Figure 7 illustrates a side view of a portion of the cable according to an embodiment of the present invention.
  • This figure illustrates a cable surrounded by jacket 710.
  • Jacket 710 has been cut away to reveal a first counter- rotating spiral 720 and a second counter-rotating spiral 730.
  • the first of these spirals may have an angle approximately equal to phi 740.
  • phi may be equal to 17 degrees. In other embodiments of the present invention, other angles may be used.
  • the second of these may have approximately the same relative angle, shown here as negative phi 742 to indicate a different absolute direction.
  • the wires in the counter-rotating spirals 720 and 730 may be easily peeled away, straightened, and soldered or otherwise electrically connected to locations in a connector plug.
  • Utilizing counter-rotating spirals 720 and 730 may also improve flexibility of the cable. For example, when the cable is twisted in a first direction, counter-rotating spiral 720 may tighten while counter-rotating spiral 730 may loosen. The tightening of counter-rotating spiral 720 may protect the internal conductors. Similarly, when the cable is twisted in a second direction, counter-rotating spiral 730 may tighten while counter-rotating spiral 720 may loosen. The tightening of counter-rotating spirals 730 may protect the internal conductors.
  • fibers may be employed by embodiments of the present invention. These fibers may be interspersed singly or in groups in one or more of the counter-rotating spirals 720 and 730. These fibers may be included for various reasons.
  • aramid fibers may be included for additional strength. Again, aramid fibers may interfere with soldering of the counter-rotating spirals 720 and 730 to locations such as a shield of, or pads in, a connector insert. Accordingly, in various embodiments of the present invention, these fibers may be pulled away from the wires in the counter-rotating spirals 720 and 730 by static electricity, air movement, or other methods.
  • the cable shown here may be made in a number of ways.
  • the wires and twisted pairs are pulled from spools and then wrapped in various layers for mechanical support.
  • the spools holding the wires and twisted pairs may be rotated during cable manufacturing. An example is shown in the following figure.
  • Figure 8 illustrates the construction of a cable according to an embodiment of the present invention.
  • a number of spools 810 may each hold one of the conductors 820.
  • spools 810 may rotate, thereby individually twisting the wires.
  • spools 810 may twist as a group, thus twisting the wires as a group.
  • spools 810 may twist one-half turn, one turn, two turns, or other fractions or numbers of turns per length of cable.
  • This combined twisting action may be referred to as planetary wire feeding, or as a planetary twist.
  • other types of assembly may be used.
  • a back twist, or no twist may be used.
  • the various conductors may be bound together, for example using tape 825.
  • a jacket may be extruded at 830, thus sealing the wires.
  • Spools 810 may hold various types of conductors or groups of conductors. For example, they may hold single conductors, coaxial cables, twisted pairs or shielded twisted pairs, or other types of conductors or groups of conductors. In a specific embodiment of the present invention, the conductors on one or more spools 810 are grouped in pairs, referred to as twinaxial, or twinax cables.
  • cables according to embodiments of the present invention may include a number of twisted pairs 520 and single wires 530, as shown in Figure 5.
  • the wires may connect to a printed circuit board in a connector insert, such as printed circuit board 120 in Figure 1 .
  • FIG. 9 illustrates a wire comb 910 that may be used to align twisted-pairs emerging from a cable according to an embodiment of the present invention.
  • Wire comb 910 may include a plurality of non-circular openings 920 and circular openings 930.
  • Twisted pairs 520 may be untwisted to the point where they fit in openings 920, then passed ' through openings 920.
  • Single wires 530 may be passed through openings 930. In this way, connectors from a cable may be aligned as they emerge from wire comb 910. This allows the conductors to be soldered to printed circuit board 120, as shown in the following figure.
  • Figure 10 illustrates a plurality of conductors 1010 that may be soldered to solder pads 1040 and 1070 on a printed circuit board, such as printed circuit board 120.
  • connectors 1010 are covered by jacket 1020.
  • Jacket 1020 may be removed thereby exposing braiding or shield layers 1030.
  • Shield layers 1030 may be soldered to pads 1040.
  • An internal isolation layer 1050 may be stripped away leaving connector terminals 1060, which may be soldered to pads 1070.
  • solder shield layers 1030 to pads 1040 and connectors 1060 to pads 1070 may be desirable to be able to solder shield layers 1030 to pads 1040 and connectors 1060 to pads 1070 in a reliable manner. Accordingly, embodiments of the present invention may employ a shaped solder bar during the soldering process. An example is shown in the following figure.
  • Figure 1 1 illustrates a method of soldering conductors to a printed circuit board according to an embodiment of the present invention.
  • twisted-pair conductors 1 120 are to be soldered to pads on a printed circuit board 1 130.
  • a shaped solder bar 1 140 may be placed over connectors 1 120.
  • Hot bar 1 1 10 may be heated, for example by passing a current from one end to another. Hot bar 1 1 10 may be lowered such that solder bar 1 140 is heated and flows, thereby soldering a shield layer of twisted pair is 1 120 to pads on printed circuit board 1 130.
  • hot bar 1 1 10 may include recesses 1 150 such that solder bar 1 140 is evenly heated. This configuration may provide a reliable solder connection between a shield braid of twisted-pair 1 120 and a pad on printed circuit board 1 130.
  • Figure 12 illustrates a connector insert according to an embodiment of the present invention.
  • This connector insert includes an insert portion 1210 to fit in a compliant connector receptacle.
  • Housing 1220 may be included such that a user can manipulate the connector insert.
  • Stress relief and cable 1230 are also included for illustrative purposes.
  • Figure 13 illustrates an exploded view of a connector insert according to an
  • Conductors of cable 1305 pass through wire comb 1 140 as described above. These conductors attach to printed circuit board 1350.
  • One or more circuits 1355 may be located on printed circuit board 1350.
  • Contacts 1365 may be supported by structure 1360, and attach to printed circuit board 1350.
  • Frame portions 1310 and 1312 may encapsulate printed circuit board 1350 and active circuitry 1355.
  • Housing portions 1332 and 1320 may form a housing around the connector insert.
  • a dust shield 1370 may be provided to protect the connector insert during transport and shipment.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Multi-Conductor Connections (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
PCT/US2011/042634 2010-06-30 2011-06-30 Method of manufacturing a connector insert, connector insert and cable Ceased WO2012003347A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
BR112012031398A BR112012031398A2 (pt) 2010-06-30 2011-06-30 método de fabricação de um inserto de conector e inserto de conector e aparelho de cabo
JP2012547345A JP5342700B2 (ja) 2010-06-30 2011-06-30 コネクタインサートを製造する方法、コネクタインサート及びケーブル
EP11738523.7A EP2589119B1 (en) 2010-06-30 2011-06-30 Method of manufacturing a connector insert
KR1020127032488A KR101408474B1 (ko) 2010-06-30 2011-06-30 커넥터 삽입부 제조 방법, 커넥터 삽입부 및 케이블

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US36043610P 2010-06-30 2010-06-30
US36043210P 2010-06-30 2010-06-30
US61/360,432 2010-06-30
US61/360,436 2010-06-30
US40805210P 2010-10-29 2010-10-29
US61/408,052 2010-10-29
US13/033,562 US8327536B2 (en) 2010-06-30 2011-02-23 Method of manufacturing high-speed connector inserts and cables
US13/033,562 2011-02-23

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EP (2) EP3285340A1 (https=)
JP (1) JP5342700B2 (https=)
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CN (2) CN202678638U (https=)
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EP3285340A1 (en) 2018-02-21
BR112012031398A2 (pt) 2016-11-08
US9385478B2 (en) 2016-07-05
KR20130018325A (ko) 2013-02-20
US20170133798A1 (en) 2017-05-11
US20120152613A1 (en) 2012-06-21
CN102332663A (zh) 2012-01-25
US20120000703A1 (en) 2012-01-05
HK1166665A1 (en) 2012-11-02
JP2013516047A (ja) 2013-05-09
KR101408474B1 (ko) 2014-06-17
US10199778B2 (en) 2019-02-05
JP5342700B2 (ja) 2013-11-13
CN102332663B (zh) 2015-01-07
EP2589119A1 (en) 2013-05-08
US8327536B2 (en) 2012-12-11
EP2589119B1 (en) 2017-11-08

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