WO2014053147A1

WO2014053147A1 - An electrical plug, an electrical jack, a jack and plug system and a method for producing an electrical plug

Info

Publication number: WO2014053147A1
Application number: PCT/EP2012/004111
Authority: WO
Inventors: Jacobus Nicolaas Tuin; Lieven Decrock; Rutger Smink; Adrianus AT J LIGTHART; Ton Van Der Bruggen; Luc Berens; Han Van het Bolscher
Original assignee: Tyco Electronics Nederland B.V.; Tyco Electronics Belgium Ec Bvba
Priority date: 2012-10-01
Filing date: 2012-10-01
Publication date: 2014-04-10

Abstract

The present invention relates to an electrical plug (2) with a plug housing (128), a male rod (4) having multiple male contact elements (6) arranged spaced from one another on an outer surface thereof, at least one insulation member (8) interdisposed between neighboring male con¬ tact elements (6) and a central conductive structure (54) comprising conductive paths (30, 44, 46, 48, 50), whereby at least some of the conductive paths being electrically connected to an assigned male contact element (6). In order to provide plural conductive paths in a compact design, the present invention proposes to arrange at least some conductive paths (26, 30, 46, 48, 50) formed by leads non-concentrically when seen in cross sectional direction of the male rod (4). The inventive jack adopted to receive the above mentioned plug has a jack housing (142) defining a receptacle (144) and holding multiple female contact elements (146) exposed within the receptacle (144) and arranged therein to contact assigned predetermined male electrical contact elements (6) when the male rod (4) of the electrical plug (2) is inserted into the receptacle (144), wherein at least eight female contact elements (146) adopted to cooperate with male contact elements (6) arranged on the outer circumferential surface of the male rod (4). The inventive jack and plug system comprises the electrical plug and the electrical jack of the invention and is characterized in that the jack housing (142) and the male rod (4) are de- signed such that, when the male rod (4) is inserted into the receptacle (144), a reference surface (166) of the jack housing (142) cooperates with a distal end section (10) of the male rod (4). In the method of the invention the plug is produced by preassembling a central conductive structure (54) of the male rod (4), preparing multiple washer elements (8) and multiple ring elements (6) and arranging the washer elements(8) and the ring elements (6) coaxially to the axis of the male rod (4) in an alternating manner, and shifting the washer elements (8) in axial direction relative to each other to assume a predetermined position, inserting the central conductive structure (54) into the washer elements (8) and the ring elements (6), to assume the final position in which the lead elements (46-50) of the central contact structure (54) can contact the assigned ring elements (6), securing the central conductive structure (54) to the washer elements (8) and the ring elements (6), and providing the housing on a terminal end of the central conductive structure.

Description

An electrical plug, an electrical jack, a jack and plug system and a method for producing an electrical plug

The present invention relates to an electrical plug with a plug housing, a male rod having multiple contact elements arranged spaced from one another on an outer surface of the male rod. Further, the male rod has at least one insulation member interdisposed between neighboring male contact elements. Within said contact and insulating elements which usually defined an outer circumferential surface of the male rod, there is provided a center conductive structure. This structure comprises conductive paths, each of which being electrically connected to an assigned male electrical contact element. Such electrical plug is e.g. known as a TRRS plug used within a plug and jack system for providing an interface for a mike line, a ground line, a (right) audio output right line and a (left) audio output left line. The output audio left and right male contacts are usually provided by the tip and a first ring when seen from a forward free, i.e. distal end of the male rod. The third male contact element when seen from the free end of the male rod may be used for transmitting a microphone or may be assigned to ground. The last male contact element, which is arranged next to the plug housing, may either be either be assigned to ground or to the mike line.

While the size of such TRRS plug, in particular a 3.5 mm TRRS plug according to AV JEITA standard has proven to be convenient for most applications in small electrical de- vices, need arises to provide a higher number of male contact elements on the outer circumferential surface of the male rod and, in addition, on the free end thereof.

However, in standard TRRS plugs, the conductive paths of the central conductive structure are usually formed by sleeves which are concentrically arranged (see e.g. PCT/JP/2009/002747) and which, at their free end, each provide the male contact ele- ments on the outer circumferential surface of the male rod. This known assembly of con- centrical tubes limits the number of conductive paths arrangeable in a compact TRRS plug. Thus, the use of respective TRRS plugs, in particular the use of plugs having a diameter of 4.4 mm or less, i.e. 3.5 mm or 2.5 mm, is limited.

In order to increase the number of interfaces provided by a respective plug, US 2011/0116747 A1 proposes a central optical path arranged in the center of the male rod and extending up to the free end thereof to provide a TX/RX interface which can be used as a USB 3.0 data interface. Further, optical interfaces are provided on a ring-shaped end face of the plug housing, which is axially projected by the male rod. While a fiber optical element provides the opportunity to transmit plural digital signals in a fast and effective way, fiber optical technology is more expensive than transmitting electrical signals through conductive paths. Further, the environment in which the plugs are used may be rough, so that the interfaces must be robust.

For those reasons, the proposal of US 2011/0116747 A1 is not satisfying for every application of an electrical plug.

Respective disadvantage also exists for a plug proposed by JP 2000-315553, which sug- gests providing a central fiber optical element within the male rod.

It is an object of the present invention to provide an electrical plug suitable to provide a plurality of male contact elements, in particular on the outer circumferential surface of the male rod, which each can be used as individual interfaces for data transport. Further, the invention deems to provide an electrical jack for such plug, which is adopted to define interfaces suitable for data transmission of data conforming with the USB 3.0 standard.

As a solution to the above object, the present invention proposes an electrical plug as specified in claim 1. The electrical plug according to the present invention is characterized over prior art in that at least some conductive paths of the central conductive structure are formed by leads which are arranged in a non-concentric fashion when seen in cross- sectional direction of the male rod. In other words, the known conductive path provided by concentric tubes forming part of the male rod is not employed. Instead, leads are arranged within the male rod exocentric to the central axis of the plug. This means that the leads are not necessarily coaxial with the central axis of the male rod nor are they each arranged concentrically to said axis in form of a cylinder. The plug is preferably a plug con- forming with the dimensions of a TRRS plug having a diameter of 4.4 mm or less, in particular a 3.5 mm TRRS plug.

An electrical plug according to the present invention may of course have a central conductive element which is arranged in a concentric way and which preferably provides an interface at the free end of the male rod. Most preferably, all conductive paths of the central conductive structure leading to male contact elements on the outer circumference of the male rod are non-concentrically arranged relative to the central axis of the male rod. Fur- ther, most preferably, leads forming the conductive path of the central conductive structure are arranged in a non-concentric fashion. Those leads can be formed from wire, by milling or screw machining, by metal injection molding, as a MID part (Molded Interconnect Device) or be made as sheet metal pieces. More preferably, those leads are ar- ranged distant from the central axis of the male rod and spaced from one another in circumferential direction of this male rod. The leads do not necessarily have to be arranged at identical radial distance relative to the central axis of the male rod or at an equidistant azimuthal distance between the leads. However, the radial distance of respective leads from the center axis of the male rod is usually between 40% and 70% of the outer radius.

Due to the nature of the constitution of the male rod, the leads have a different axial length. At least immediately adjacent to the plug housing, multiple leads are spaced from one another in circumferential direction when seen in a cross-sectional directional of the male rod. Accordingly, the leads are preferably arranged non-concentrically relative to each other. Respective constitution may be embodied by some of the leads, preferably by all leads leading to male contact elements at the outer circumferential surface of the male rod and most preferably may be embodied for all leads leading to male contact elements forming differential pairs.

According to a preferred embodiment of the present invention, those individual leads are spaced from the central axis of the male rod and from one another in the circumferential direction. The signal leads preferably lead to male contact elements for data transfer at the interface, wherein said male data contact elements are preferably provided as pairs with two male data contact elements arranged adjacent to each other and interdisposing therebetween the insulation member, and assigned to the + side and the - side of a specific data protocol of the pair.

According to a further preferred embodiment of the present invention, the signal leads are arranged spaced from and around a core conductive element, wherein said core conductive element defines a conductive path extending partially or completely through the male rod. Respective core conductive element preferably is a core ground element which is electrically connected to one or plural male contact elements assigned to ground. Those male ground contact elements may be directly, i.e. physically, connected to the core conductive element. However, such assignment of a male contact element may likewise be connected to ground by means of a capacitor and define an ID. A preferred embodiment for such capacitor will be described hereinafter. The core conductive element is preferably designed with a non-concentrical and/or a non-circular cross-section, but does not necessarily have to be non-concentrical. The core conductive element is usually formed of a sheet metal which is selected to also contribute to the structural integrity of the male rod. Accordingly, the core conductive element preferably defines a central metallic structure which stiffens the male rod and, furthermore, can be used as a conductive path. The shape of such central metallic structure can be such that it does not interfere with the space required for the leads. In particular, a sheet metal material may be bent to form the core conductive element to add sufficient rigidity to the male rod, while leaving sufficient room for arranging the leads within the central conductive structure.

According to a further preferred embodiment of the present invention, an inner lead is arranged within the core conductive element. This inner lead is in particular suitable for de- fining at least one male contact element as a floating ground male contact element by connecting this element to ground by means of a capacitor. Accordingly, the inner lead is usually arranged within the core conductive element in an insulated fashion and with minimum distance thereto. Further, the inner lead that forms a floating ground, when not connected in the termination section, can also be connected to ground directly in a termi- nation section or via a resistor.

In the present invention, the terms "insulated" and "conductive" refer to electrical properties and need to be understood as "electrically insulated" and "electrically conductive", respectively.

According to a further preferred embodiment of the present invention, a central lead is provided which usually is arranged on the central axis. Respective central lead is preferably arranged within the core conductive element. However, for the use of the central lead as a further conductive path independent of the conductive path which can be provided by the core conductive element, respective central lead is preferably supported within the core conductive element in an insulated fashion. According to a further preferred embodiment of the present invention, a proximal end of the signal leads each provides a termination interface. Further, the termination interfaces of plural signal leads are arranged in one plane. Accordingly, and as opposed to prior art, where the termination interfaces are spaced from one another in axial direction of the male rod, this preferred embodiment of the present invention contributes to a compact design of the electrical plug. Preferably, termination interfaces of different signal leads are spaced from one another in circumferential direction within the one plane for ease of electrical contacting at the termination interface. Within said one plane or enclosed in the vicinity thereto, the core conductive element may likewise provide a termination interface for electrical contact to the core conductive element. The aforementioned inner lead is usually not provided within the one plane with its termination interface. The termination interface of said inner lead as well as the termination interface of the central lead usually projects the one plane in axial direction. Accordingly, the distal end of the inner lead and/or the central lead regularly projects the one plane in axial direction to the proximal end of the electrical paths.

According to a preferred embodiment of the present invention, the male contact elements and the at least one insulation member are arranged so as to provide a shell for a room adapted to receive plural conductive paths. According to this preferred embodiment, the male conductive elements are formed by rings and the at least one insulation member is formed by a ring-shaped washer element. The outer circumferential end section of said washer element cooperates with the neighboring ring elements, while an inner circumfer- ential end section of the washer element cooperates with a core element extending in axial direction of the male rod. This core element may be formed by the aforementioned core conductive element. This preferred embodiment can as such form a separate invention independent of the limitation contained in the characterizing clause of claim 1. This invention is defined by the preamble of claim 1 and the characterizing clause of claim 8. In an electrical plug according to the aforementioned preferred embodiment, the ring elements are conductive elements which are preferably arranged floating, i.e. are usually sandwiched only between the washer elements. Thus, the outer shell defining the outer circumferential surface of the male rod is usually supported against the core element only be means of the one or more washer elements. Apart from that, a tip provided at the free end of the male rod may likewise directly be connected to the core element in a conductive or insulated manner. On a regular basis, the ring elements have a cylindrical outer surface, while any non- cylindrical outer circumferential surfaces of the male rod are preferably formed by the washer element or the plural washer elements, which can be formed as injection molded parts, with a rather complex geometry at economical costs. In order to reduce mutual electrical coupling between the neighboring contact elements, an axial end section of the washer element and/or an axial end section of the ring element is provided with a contour reducing the material provided at an interface between the two elements. However, in order to thoroughly support the ring element, the washer element usually supports an inner circumferential surface thereof. According to the preferred em- bodiment of the present invention, the washer element is provided with a flange, i.e. with a section having a reduced thickness in radial direction, defining an outer circumferential surface of the washer element supporting the ring element. In addition or alternatively, the ring element can be provided with a flange defining an inner circumferential surface which abuts against the assigned washer element, preferably against the outer circumferential surface defined by the flange of the washer element. Those measures are suitable to reduce the surface area where coupling between the ring elements occurs, which improves impedance. For ease of manufacturing, a circumferential outer end surface of the washer element and/or a circumferential inner end face of the ring element and/or an outer circumferential end face of the washer element may be chamfered, which facilitates as- sembly of the two elements and reduces the area of the ring that electrically couples with the neighboring ring.

As a contribution to a further reduction of the mutual electrical coupling, the washer element is provided with gaps arranged between the inner circumferential end section and the outer circumferential end section thereof. Those gaps are preferably arranged in circumferential direction space from one another. Eventually, the washer elements can have rather thin spokes ending between the inner circumferential end section and the outer circumferential end section, said spokes defining the gaps between them. Said gaps can be used to guide individual leads through the male rod in axial direction thereof and position the leads in radial direction securely prevent the signal leads from contacting each other. Accordingly, the gaps of plural washer elements arranged axially distant from each other are preferably aligned so as to define one, preferably multiple, axial channels extending through the male rod, each channel receiving not more than one lead. According to a further preferred embodiment, which, in combination with the features of the preamble of claim 1 , can be considered to define an independent invention, a core element is formed of sheet metal cut and bent to provide, at the free end thereof, at least one snap arm having positive locking means. At the tip of the male rod, a tip element, regularly a machined part defining the male rod is formed. This tip element has an engaging section adapted to cooperate with the positive locking means of the snap arm so as to provide a positive fit between the core element and the tip element. Such constitution facilitates manufacturing of the tip with exact dimensions e.g. by machining, while the tip element can easily be connected to an inner supporting structure, i.e. the core element of the male rod.

According to a preferred embodiment thereof, there is provided a blocking element received within the core element and cooperating with the snap arm to secure the positive fit between the core element and the machined tip. This blocking element may preferably be formed by an insulating cladding arranged between the core element, preferably the core conductive element, and a central lead. Most preferably, the insulating cladding may be formed on the central lead and attached thereto to form a unitary center pin. Accordingly, a reduced number of parts need to be handled when assembling the electrical plug according to the present invention. Preferably, the blocking element is movable in axial direction and is provided with a cut-out allowing a certain degree of elastic bending of the snap arms to snap into the engaging section of the tip element, when the cut-out is arranged radially inwards of the snap arm. Upon axial displacement of the blocking element, respective elastic bending is prevented by the blocking element and, hence, the positive fit is unreleasably secured.

Regularly, the sleeve of the TRRS-style plug is a contact, i.e. a signal contact, to be con- nected with a first signal contact of the jack. Due to the geometry of the sleeve, electric transmission of data signals via a pair comprising the sleeve and a first ring contact element arranged adjacent thereto for carrying a differential pair signal is insufficient. In particular, the high speed transmission of signals would be deteriorated in such differential pair formed by two neighboring contact elements. Accordingly, and with a preferred em- bodiment of the present invention, it is proposed to assign a sleeve provided at a proximal end side of the male rod to ground. In other words, the sleeve defines a sleeve male ground contact element of the male rod. If the sleeve is considered to define a first contact position of the male rod directly adjacent to the plug housing, the second and third male contact elements would be suitable to carry a differential signal in a proper way. The sleeve male ground contact according to the aforementioned preferred embodiment of the present invention is usually of shorter length than the sleeve of known TRRS-style plugs. This aspect can define a separate independent invention. Accordingly, the features of the preamble of claim 1 together with the features contained in claim 14 may define an independent aspect of the present invention.

According to a preferred embodiment, the sleeve is connected to a cable braid of a cable connected to the plug housing to provide an extension of the shield. According to a preferred embodiment of the present invention, a male electrical contact element assigned to ground is arranged between two male differential pairs. With respective measure, the cross-talk between signal pairs can be reduced. The respective male electrical contact arranged between the two male differential pairs may either be directly connected to ground or be assigned to ground by means of a capacitor. Respective pro- posal is likewise made preferably for connecting the sleeve male ground contact element to ground. By means of the capacitor, the male ground contact element arranged between the two male differential pairs and/or the sleeve male ground contact element provide a double function and can define ground at high frequencies only, while defining ID as a signaling contact for low frequencies/DC only. Within the central conductive structure, the ID is preferably located sufficiently close to a ground conductive element of said central conductive structure, which provides a sufficiently large area for creating a capacity which is high enough to couple higher frequencies to ground. However, the ID is not physically connected to ground leaving it free to be used as a signaling contact element for DC and low frequencies, as for that the capacity is not sufficient to have a significant coupling to ground. With the proposed assignment to ground by means of a capacitor, the ID- functionality can be created without adding a capacitor as a discrete component.

The aforementioned embodiment may likewise define an independent aspect of the present invention. Thus, the features of claim 17 may specify together with the preamble of claim 1 an inventive electrical plug. According to a preferred embodiment, the core element defines a core conductive element providing a core ground conductive path electrically connected to at least one male conductive element defining a male ground contact element. This core conductive element defines a capacity surface. The capacity surface is usually formed by a surface of a core conductive element formed of a metal material, preferably of a sheet metal material. Further, according to this preferred embodiment of the present invention, an inner lead is arranged radially inward of the first capacity surface to provide a compact constitution. Respective inner lead defines a second capacity surface of a floating ground conductive path. The first and the second capacity surfaces, which are usually aligned essentially parallel to each other, form a larger floating ground coupling capacity between the core conductive element and the floating ground conductive path, then a coupling capacity be- tween signal leads and the core ground conductive path. Further, in order to assign the male ground contact element to ground, the floating ground conductive path is physically connected to this element. With respective preferred embodiment, a simple and rather compact capacitor is provided for assigning the sleeve male ground contact element and/or the male ground contact element to ground without adding a capacitor as a sepa- rate component.

The aforementioned specific constitution of the core conductive element having received therein an inner lead adapted to provide a capacity forms an independent aspect of the present invention, which is claimed as such, i.e. only in combination with the features contained in the preamble of claim 1. According to a further preferred embodiment of the present invention, the core conductive element is made of a sheet metal defining a polygon structure with a gap extending in axial direction of the male rod. One or more sheet metal pieces can be combined and/or be bent to form the polygon structure. The gap can be provided by a hole in a sheet metal piece or a separation between two adjacent sheet metal pieces. The inner lead is ar- ranged within the polygon structure and coupled to the male ground contact element via a contact arm extending through the gap. A polygon structure in the meaning of the present invention in particular is a structure in which straight surface sections are connected to each other at an outer corner portion and only intersect at their respective ends. A polygon structure can e.g. be a triangle, a square, a pentagon, a hexagon or a heptagon. Preferably, the signal leads are arranged adjacent to the straight surface sections and generally on an outer side of the polygon structure.

The polygon structure as such will be explained in greater detail hereinafter. According to a further preferred embodiment of the present invention, a dielectric sheet is provided between the first capacity surface and the second capacity surface. This dielectric sheet, which may be formed by a plastic foil, covers at least one of the two capacity surfaces. The insulation material of which the dielectric sheet is made preferably has a higher permittivity than the insulating material of the insulating members of the male rod. With such properties, the capacitor can be improved for defining ground at higher frequencies, in particular high speed data transfer, while defining an ID signaling pin for low frequencies or DC only. The dielectric sheet preferably has an adhesive coating on one side for coupling the core conductive element to the inner lead. Accordingly, the dielectric sheet is sandwiched between the first and the second capacity surfaces and acts as a coupling means in the assembly of the electrical plug and/or under conditions of use thereof.

In this respect it is preferred to provide a floating ground coupling capacity that is such that, for the data rates under consideration, it acts as a short and for DC signaling acts as an open.

The further preferred embodiment of the present invention tries to cope with problems which may arise from the fact that single leads are circumferentially arranged and, thus, are provided in a non-concentrical way relative to each other and to the central axis of the male rod. Such positioning of the conductive path is liable to degrade the performance as a conductive path assigned to ground is no longer provided between or around signal lines, in particular between individual signal pairs. Thus, in order to provide an electrical plug adapted to provide high speed data transfer in particular conforming with the USB 3.0 standard in a rather compact plug having a diameter of e.g. 4.4 mm or less, it is suggested that the central conductive element comprises one or more core ground conduc- tive paths which are electrically connected to at least one male contact element defining a ground contact element. The one or more conductive paths are - when seen in cross- sectional direction of the male rod - arranged to define outer edges of a polygon structure. As already mentioned above, respective polygon structure can be a triangle, a square, a rectangle, a pentagon, hexagon or heptagon, octagon and so forth. This polygon structure can be formed by a single central conductive element preferably of polygonal shape. It may likewise be feasible to arrange single elements each defining a core ground conductive path and to arrange each of the conductive elements at the corners of the polygon structure to be formed. Essentially between those individual conductive elements, signal leads are arranged on a regular basis in the form of pairs, i.e. single leads of same protocol next to one another. A respective polygon structure can likewise be formed by ground plate elements which are arranged in a position corresponding to the surface sections of a polygon structure. The lateral ends of two plate elements may either contact each other at the outer edge of the polygon structure or be provided immediately adjacent to said outer edge with small distance, thereby defining the outer edges of the polygon structure. The lead signals are usually arranged at an outer circumferential side of the polygon structure.

According to a preferred embodiment of the present invention, coupling of the signal leads is avoided to a great extent if respective signal leads which connect to male contact elements defining male signal contact elements are arranged between parallel ground lines. Those lines intersect neighboring edges of the polygonal structure and extend perpendicular to a connection line. This connection line is the line connecting the neighboring outer edges. Respective constitution is seen in a cross-sectional view relative to the axial extension of the male rod. Obeying this provision helps avoiding any placement of signal leads out of the shielding effect of the outer edges of the polygon structure. Respective provision for preventing coupling of the single leads discussed above can form a separate independent element of the present invention. Specifically, one or more ground conductive paths defining outer edges of a polygon structure may specify an independent inven- tion along with the features contained in the preamble of claim 1 as filed.

According to a further preferred embodiment, at least one, preferably plural ground contact elements are provided on the outer circumference of the male rod axially spaced from one another. For facilitating contacting those male ground contact elements to ground, a core ground contact element is preferably provided, which is electrically connected to all ground leads defining the outer edges of the polygon structure. Preferably, the core ground contact element actually is made of an electrically conductive material and shaped in the form of the polygon structure. The one or more plural male contact elements are - according to this preferred embodiment - formed by separate rings which are arranged on the outer circumference of the male rod. Those ring elements are, for ease of assembly, force-fitted on radial projections of the core ground contact element. As the same is made of an electrically conductive material, the force-fit will not only lead to fixation of the ring elements, but also to a physical electric connection between the core ground contact ele- ment and each ring element. In case the core ground contact element is made of a sheet metal material, the radial projections thereof can be formed by cutting and bending of a sheet metal section. Radial projections formed in this way can have a certain degree of elasticity to secure the ring element in axial position relative to the core ground contact element.

In order to enhance data transfer through the electrical plug, it is preferred to provide at least one optical interface exposed on the outer circumferential surface of the male rod. For this purpose, the male rod preferably comprises a rib section which projects in radial direction an essentially cylindrical surface section of the male rod and extends in axial direction thereof. On the radial end face thereof, the rib section exposes the optical interfaces. The optical interface can be provided on an axial position of one or more male contact elements, which can either be assigned to ground or to a signal line. As the rib section does not project over the entire circumference of the male rod, a major circumferential portion thereof can still be utilized to provide an interface at the axial position of the optical interface. Accordingly, the position of each male contact element on the outer circumference of the male plug may not be altered for the improved signal transfer via an optical interface.

According to a preferred embodiment, an optical transceiver is provided, which has an input side being connected to a fiber optical element. The output side thereof is electrically connected to at least one of the male contact elements. The optical transceiver is preferably arranged within the plug housing for rendering the preferred constitution compact and robust.

The electrical plug according to the present invention may preferably be used in a wireless application. Thus, it is preferred to provide a wireless transceiver usually arranged within the plug housing. The wireless transceiver has an input side defining a wireless interface and an output side being electrically connected to the male contact elements of the electrical plug. Respective wireless transceiver can e.g. have a transmission at 60 GHz and enables wireless connectivity to the electrical plug, thereby avoiding any cable. The wireless connectivity usually provides the pins conforming with the USB 3.0 standard. The present invention furthermore provides an electrical jack for the afore-discussed electrical plug. The jack has a jack housing defining a receptacle and holding multiple female contact elements exposed within the receptacle and arranged therein to contact assigned predetermined male electric contact elements of the electrical plug, when the male rod thereof is inserted into the receptacle. The inventive electrical jack defines at least nine female contact elements adapted to cooperate with male contact elements arranged on the outer circumferential surface of the male rod. The nine contact elements exposed in circumferential direction of the receptacle are each held within the jack housing in an insulated manner. Accordingly, the inventive electrical jack is adapted to provide an electrical interface for a USB 3.0 protocol, while avoiding strong coupling between the female contact element despite the fact that the receptacle is preferably designed so as to receive a plug having an outer diameter of 4.4 mm or less, e.g. 3.5 mm (TS, TRS or TRRS plug) as usually some contact elements are coupled to ground.

According to a preferred embodiment of the present invention, the first, third, sixth and ninth female contact elements counted from an entrance opening of the receptacle are positioned such that those female contact elements are adapted to contact the first, the second, the third and the top male contact elements, respectively, arranged on the outer circumferential surface of a 3.5 mm plug according to AV JEITA standard. Thus, the inventive electrical jack is not only suitable to receive the inventive electrical plug to connect the at least nine female contact elements of the inventive jack. The jack is furthermore suitable to also make contact with a standard 3.5 mm plug. Accordingly, the inventive electrical jack can be used with commonly available plugs for audio signals, and optionally for charging on a TRRS jack. It can furthermore be employed for data transfer conforming with the USB 3.0 specification e.g. over a USB 3.0 connector attached either to the contacts of the electrical jack or to the contacts of the electrical plug.

In addition to the at least nine female contact elements adapted to cooperate with male contact elements arranged on the outer circumferential surface, the electrical jack of the present invention may preferably have, near an end face of the receptacle, a power contact element which cooperates with a male power contact element exposed on the free end of the male rod, thereby providing a charging voltage in the plug, which is advantageous for some applications of the electrical jack/electrical plug system described in the present application.

In order to reduce the mutual electrical coupling between male conductive elements of the rod being inserted into the receptacle, the present invention proposes a slot recessed within the material forming the jack housing. This slot is open at least in radial direction to the receptacle. The slot is preferably arranged at a location of a female contact element defining a high speed data contact element, more preferably at a location of a female high speed data pair, as seen in axial direction, i.e. longitudinal direction of the receptacle. This slot may expose the female contact element defining a female high speed data contact element or, more preferably a female high speed data pair. According to this preferred embodiment, the slot may extend in circumferential direction, i.e. provide a ringshaped void around the at least one contact element. Alternatively, plural slots may be circumfer- entially spaced from each other, each extending preferably in axial direction. Accordingly, a respective slot is recessed in the wall of the receptacle receiving the mating plug. Such slot essentially reduces the amount of dielectric material and thereby the electric coupling which may cause problems in particular in the course of high speed data transmission.

In particular, for reducing cross-talk between two female data differential pairs arranged within the housing and being exposed to the receptacle, it is proposed - according to a preferred embodiment of the present invention - to arrange the female contact elements of the first female data differential pair diametrical to the female contact elements of the second female data differential pair, in particular in the event the two female data differential pairs are arranged axially next to each other with a female contact element being assigned to ground interdisposed between the two female data differential pairs. Preferably, a female ground contact element is interdisposed between any first and second data differential pairs provided by the electrical jack. More preferably, each data differential pair is arranged between female ground contact elements.

The electrical jack is adapted to also provide an optical interface and preferably has an axial slot open to the receptacle and to an entrance opening thereof and defining a radial end face which is provided with the optical interface. This radial slot is recessed in and radially projects from a general cylindrical receptacle with circular cross-section adapted to receive the male rod and allows insertion of an optical interface provided by the electrical plug on the rib section previously discussed but also contacting of the plugs without respective optical interface or general TRRS plugs having only a limited number of male contact elements. This aspect can form a separate independent invention defined by the preamble feature of claim 28 and the features of claim 33. The common mechanical reference to the insertion depth of a standard TRRS plug is a wall of the sleeve, i.e. a wall defined by the fastening, i.e. proximal end side of the plug. This wall abuts against a front surface of the jack or against a cover covering the jack or parts thereof. Such cover is often used in mobile devices to create a more appealing de- sign. When using a cover, a drawback is that the insertion depth of the TRRS plug is not as precise as required. Thus, there may be a mismatch between the male contact elements of the male rod and the female contact elements held within the jack housing. As the axial extension of those conductive elements in a standard TRRS plug is fairly high, this mismatch does not cause a problem. However, in a small plug of a diameter of 5.5 mm or less having multiple contact elements provided on the outer circumferential surface of the male rod conforming with the USB 3.0 standard, each male contact element being axially spaced apart from the neighboring contact element with an insulation member interdisposed therebetween, such mismatch may lead to misconnection or no connection if the plug element is inserted into the receptacle. In order to cope with this problem, the present invention proposes to design the jack housing and the male rod such that, when the male rod is inserted in the receptacle, a reference surface of the jack housing cooperates with an end section at a free end of the male rod. In other words, the reference surface specifying the insertion depth of the electrical plug into the electrical jack of an inventive system comprising both the jack and the plug is determined by an inner end section of the jack housing and not - as in prior art - by mating surfaces on an opposing end. Thus, the jack may e.g. be covered to improve the outward appearance of the jack and plug system specified without interfering with the desired precision in making contact within the receptacle between the jack and the plug.

The jack and plug system specified above preferably has front contact elements providing a power interface. For this interface, the electrical plug usually has a male power contact element at the free front end face thereof, usually extending perpendicular to the axis of the male rod, while an assigned female power contact element is arranged near the reference surface, i.e. close to the bottom of the receptacle. Further, the sleeve of the plug preferably is so short that it is no longer possible to contact it with a female jack contact, as that would almost have to stick out of the device containing the jack. Still, it is beneficial that, in the plug, this sleeve is connected to ground. So, in the plug, the first differential pair is surrounded by ground but, in the jack, it does not have ground on the "front" side but only on the side deeper in the jack, which is the ID contact. Accordingly, the sleeve is not a contact in the sense that it interfaces with a female contact of the jack. This is in contrast to a standard TRRS sleeve.

According to a further preferred embodiment, the jack and plug system provides an interface conforming to a USB 3.0 protocol between the jack and the plug when the male rod is inserted into the receptacle. In such interface, the sleeve of the male rod takes part in the transmission of data signals. The sleeve usually is coupled to ground. Counted from an entrance opening of the receptacle, the first two contact elements provide a differential D-pair of the USB 3.0 protocol. The next, i.e. third contact element, provides a ground or a floating ground interface. The fourth and fifth contact elements provide a differential pair interface of the USB 3.0 protocol, preferably the SSTX data pair. The sixth contact element provides a ground interface. The seventh and eighth contact elements provided on the outer circumferential surface of the male rod provide a differential pair interface for the USB 3.0 protocol, preferably the SSRX interface. The ninth contact element, which is usually provided by a tip element of the male rod, is coupled to ground. The present invention furthermore specifies a cable assembly for a serial digital communication having an electrical plug as specified in any of claims 1 to 27 or an electrical jack as specified in any of the claims 28 to 33 connected to a cable. At least some of the male or female contact elements and the conductive paths connected thereto are provided as one or more differential pairs. Each differential pair preferably is connected to a pair within the cable. Such pair within the cable may be a shielded pair or a twisted pair or a parallel pair or a shielded version of those pairs.

Further, the present invention specifies an electrical device comprising a plug for data transmission according to any of claims 1 to 27 or an electrical jack as specified in any of the claims 28 to 33. At least some of the male elements of said plug or of said jack are provided as one or more differential pairs which are connected to a serial communication interface and configured to transmit or receive serial data.

The present invention furthermore specifies an economical method of producing the plug of the present invention. According to this method, a central conductive structure of the male rod is preassembled. Multiple washer elements and multiple ring elements are pre- pared. Then, the washer elements and the ring elements are arranged coaxially to the axis of the male rod in an alternating manner. Accordingly, a ring element will be arranged between two washer elements. This alternating arrangement of washer elements and ring elements is usually terminated by a washer element. At the proximal end of the shell defined by the washer elements and the ring elements, a sleeve element is usually provided. If needed, the washer elements are then shifted in axial direction relative to each other to assume a predetermined position. This predetermined position defines the final axial distance between all washer elements required to properly position the conductive ring elements in the predetermined axial position along the axial extension of the male rod. This final axial distance of the elements is embodied at the final product. Before, during and/or after shifting the central conductive structure is inserted into the washer elements and the ring elements, i.e. the shell provided by the two elements, to assume a final position in which lead elements of the central conductive structure can contact the assigned ring elements. After that, the central conductive structure is secured to the washer elements and the ring elements. Usually, the central conductive structure is directly connected to the washer elements and indirectly connected to the ring elements by means of the washer elements. In other words, the ring elements do not make direct contact to the central conductive element, but are secured thereto by means of and between the washer elements in the final position. Possibly, the ring elements are held with a slight axial play between the assigned washer elements. Finally, a housing is provided on a terminal end of the central conductive structure. This method step is usually the last step of making the electrical plug. In the course of fixing the housing to the terminal end, cables are attached to the terminal ends of each conductive path of the central conductive structure.

The inventive aspect of the present invention resides in the proper alignment of the elements defining the outer shell of the male rod, i.e. the washer elements and the ring elements. In the inventive method, only the washer elements are handled to assume the pre- determined position. As the ring elements are arranged between the washer elements and supported by flanges which allow a certain axial displacement between the washer elements and the ring elements without losing contact between the two elements, the washer elements can be shifted to the predetermined position. The ring elements follow respective predetermined positions and assume a position therebetween which is the correct position for making contact with a mating female contact element of a jack. Shifting can be done as the elements are arranged in an alternative manner or thereafter. Shifting of the washer elements can be attained either manually or mechanically. In case of mechanical shifting, a clamping force acting against the outer circumference of the washer element may e.g. fix the same to a shifting tool which can shift respective washer element into the predetermined position and hold the same in said position. According to a preferred embodiment of the inventive method, the washer elements are secured to the central conductive structure by expanding the same in radial direction. Accordingly, the central conductive structure is adapted to be deformed at least elastically from a non-expanded state in which the central conductive structure can fit through the washer elements, in particular the inner circumferential end section thereof, and slide through the washer elements with a reduced sliding resistance, while securing the washer elements by means of a press fit, preferably for obtaining a positive fit and/or a press fit in the expanded state.

Respective expanded state is usually assumed by inserting a tooling pin into the central conductive structure. To avoid a relaxation of the central conductive structure upon extrac- tion of the tooling pin, it is preferred to introduce a center pin into the central conductive structure from another end. This center pin is simultaneously introduced into the central conductive structure as the tooling pin is extracted out of the central conductive structure. Accordingly, after initial expansion of the central conductive structure, a pin is always introduced for securing the expanded state. The center pin finally forms part of the pro- duced electrical plug.

In order to thoroughly secure the washer elements in the predetermined position, bosses provided on the outer circumferential surface of the core conductive element are preferably urged between the washer elements to finally position the washer elements in axial direction by means of a positive fit. This positive fit is defined by two neighboring bosses sandwiching in between an assigned washer element.

According to a further preferred embodiment of the inventive method, the center pin is introduced into the core conductive element to an intermediate position in which at least one snap arm of the core conductive element is level with cut-out provided on the outer circumference of the center pin. This cut-out is usually formed within an insulated cladding of the center pin which circumferentially encloses a central lead adapted to provide sufficient rigidity to the center pin. In said intermediate position, the at least one snap arm of the core conductive element is adapted to flex to a certain degree into the cut-out. Thus, a tip element can be snapped onto the snap arm as the center pin is held in the intermediate position. By snapping the machined tip element to the snap arm, respective tip element is electrically and mechanically connected to the core conductive element. Finally, respective tip element is prevented from being released from the snap arm after the center pin has been further introduced into the core conductive element to assume the final position. By further introducing the center pin into the core conductive element, the cut-out passes the snap arm. The outer circumferential surface of the center pin in the final position is essentially fitted against the snap arm, thereby preventing any flexing movement thereof.

According to a further preferred embodiment of the inventive method, at least one ring element is electrically connected to a contact arm of an inner lead. This inner lead is arranged within the preassembled central conductive structure. Connecting of this arm to the assigned ring element is achieved by radially pushing the contact arm against respec- tive ring element after the central conductive structure has been inserted into the washer element. In other words, the contact arm is plastically deformed after the central conductive structure has been inserted into the washer elements and the ring elements. In this way, the contact arm is not in the way when the central conductive structure is inserted into the washer elements. Deformation is usually attained by the tooling pin inserted into the central conductive structure and preferably secured thereafter by the center pin. Usually, the contract arm is at least plastically deformed by means of the tooling pin.

Further features, advantages and details of the present invention will become apparent from the following description of preferred embodiments in connection with the drawing.

In the drawing Fig. 1 is a perspective side view of the main components of an embodiment of an electrical plug of the present invention;

Fig. 2 is a partially cut perspective view of the embodiment shown in Fig. 1 ;

Fig. 3 is a perspective side view of the embodiment of Figs. 1 and 2 with some parts taken away for visualizing some components of the central conductive structure thereof; is a perspective sectional view along Line IV-IV of Fig. 2; is a partially cut perspective view elucidating leads being connected to ring elements as embodied in the embodiment according to Figs. 1 to 4; show alternative ways of connecting leads to ring elements; is a perspective side view of a variant of the embodiment according to Figs. 1 to 4 with some parts taken away for visualizing some components of the central conductive structure thereof; is a perspective side view of a second embodiment of a core conductive element; a perspective side view of the second embodiment in accordance with Fig. 9 with further elements of the male rod with some parts taken away for visualizing some components of the central conductive structure thereof; a rear view of the second embodiment according to Figs. 9 and 10; a perspective top view of a termination interface of a third embodiment; a schematic representation of the conductive paths of the first, second and third embodiments of the central conductive structure; a schematic partially cut-away longitudinal view of a length piece of the male rod; a schematic top view of a washer element; a longitudinal sectional view of a ring element; a cross-sectional view of the male rod of the first embodiment, with leads inserted and without core conductive element; a longitudinal sectional view of the male rod in accordance with Fig. 17; Fig. 19 a perspective side view of a proximal end section, in which parts of the central conductive structure have been but away;

Fig. 20 a longitudinal sectional view of the male rod of the first embodiment with the core conductive element inserted; Fig. 21 a perspective side view of the forward end of the core conductive element with a tip element being attached thereto;

Fig. 22 a side perspective view of a fourth embodiment of the inventive plug;

Figs. 23 to 29 drawings visualizing different steps of an embodiment for the inventive method for manufacturing the inventive plug; Fig. 30 a side perspective view of an embodiment of the electric jack of the present invention;

Fig. 31 the embodiment according to Fig. 30, with the jack housing taken away;

Fig. 32 a schematic drawing of a length piece of the male rod inserted in a receptacle of the present invention; Fig. 33 a cross-sectional view along line XXXIII-XXXIII according to Fig. 32;

Fig. 34 a cross-sectional view in accordance with Fig. 33 for an alternative embodiment;

Fig. 35 a partial cut-away side view of am embodiment of a plug and socket system of the present invention, and Fig. 36 an alternative embodiment of the jack of the present invention suitable to receive the plug depicted in Fig. 22.

Figures 1 and 2 show the male portion of an electrical plug 2, essentially a male rod 4 thereof. The male rod 4 has plural ring elements 6 and washer elements 8 interdisposed between the ring elements 6. On a free end thereof, the male rod 4 has a tip element 10 which is a machined part. On the opposed end, i.e. the fastening end, the washer element 8.1 is sandwiched between an adjacent ring element 6.1 and a sleeve 12 made of a metal material and having a cylinder section 13 having a diameter of the neighboring washer element 8.1. Partially within said sleeve 12 and partially projecting a distal end thereof, there is provided an organizing sleeve 14 made of an insulating material. On its outer circumferential surface approximately in the axial mid, the organizing sleeve 14 provides a ring of radial stops 15 spaced from one another in circumferential direction.

As evident form Figures 1 and 2, the ring elements 6 each have a cylindrical surface, while some of the washer elements 8.7 and 8.8 are chamfered on their outer circumferential surface to arrange for a smooth outer circumferential surface between ring elements 6.8, 6.7 and 6.7, 6.8, respectively, of different outer diameter. The maximum diameter of the male rod 4 of the example is 3.5 mm. The sleeve 12 comprises two sleeve flanges 16, 18 radially projecting this maximum diameter. The depicted embodiment has the following dimension in axial direction: The thin washer elements 8.1 to 8.4, 8.6, 8.7 and 8.9 have a typical axial length of 0.4 mm. Each ring element 6 has an axial length of typically 0.7 mm. The larger cylindrical washer element 8.5 has an axial extension of 0.9 mm. The larger chamfered washer element has an extension of 0.8 mm.

The distal end of the tip element 10 is projected by an end section of a center pin 20 comprising an insulating cladding 22 circumferentially surrounding a central lead 26 projecting through the entire axial length of the male rod 4 and arranged coaxially with the central axis of the male rod 4. The central lead 26 defines a male front contact element 24 at a distal end of the plug 2. At the proximal end of the embodiment, the central rod 26 can be seen with its proximal end section 28 defining a termination end for coupling a cable thereto. Between the insulating cladding 22 of the center pin 20 and the organizing sleeve 14 at the proximal end, an inner lead 30 can be seen with its proximal end section 32. The inner lead 30 defines a floating ground path within the male rod 4 and is shown in greater detail in Fig. 24. The inner lead 30 defines two contact arms 34, 36, both made by cutting and bending a sheet metal material forming the inner lead 30. In Fig. 24, the contact arms 34, 36 are shown prior to final assembly. In such initial position, the contact arms 34, 36 project an inner surface 38 of the inner lead 30. On an outer surface 40 of the inner lead 30, there is provided a dielectric sheet 42 which has adhesive on a surface facing the in- ner lead.

The inner lead 30 is arranged within a core conductive element 44 shown in greater detail in Figs. 3, 4 and 8. This first example of a core conductive element 44 is made of bent sheet metal, receives the center pin 20, has a triangular cross-section projecting through a coordinated inner opening of the organizing sleeve 14 and is circumferentially surrounded by signal leads 46.1 , 46.2; 48.1 , 48.2; 50.1 , 50.2, identified e.g. in Figs. 3 to 5 and 8.

As evident e.g. from Figs. 3 and 27, the signal leads 46.1 to 50.2 are received in guiding slots 52 provided on the outer circumferential surface of the organizing sleeve 14 and aligned in axial direction of the male rod 4. By retaining the signal leads 46.1 to 50.2 in a respective guiding 52, the signal leads 46.1 to 50.2 extend essentially parallel to side surfaces of the triangular core conductive element 44 and with distance thereto (see Fig. 3).

As evident in particular from Fig. 5, the signal 46.1 to 50.2 are contacted against an inner circumferential surface of an associated ring element 6 by a spring force. The free ends of each signal lead 46.1 to 50.2 are slightly bent inwardly to facilitate introduction and sliding of the signal leads 46.1 to 50.2 in the course of manufacturing the embodiment.

Alternative ways to electrically connect signal leads to ring elements are depicted in Figs. 6 and 7. A lead 46 may either be soldered or welded to an assigned ring element 6 (see Fig. 6) or be integrally formed with the ring element 6 (see Fig. 7).

The center pin 20, the core conductive element 44 of a variant to the first embodiment as well as the signal leads 46.1 to 50.2 form a central conductive structure 54 of the embodiment. As evident e.g. from Fig. 8, the core conductive element 44 has different axial locations where radial projections 56 are cut out and radially bent at corner portions of the triangular sheet metal core conductive element 44 to project the corner portions. As in particular evident from Fig. 8, the radial projections 56 cooperate with an assigned ring element 6.6 to electrically and mechanically connect the ring element 6.6 to the core conductive element 44. In fact, the respective ring element 6.6 is press fitted against the core conductive element 44 by means of the radial projections 56. The core conductive element 44 can be made also of two sheet metal pieces. Hence, a segment 58 which is parallel to the inner lead 30 is formed by a sheet metal piece separate from a bent sheet metal element 59 that is bent to adopt a triangular shape and adopted to receive the segment 58 (cf. Figs. 25, 26). By cutting prior to bending of the sheet metal forming the segment 58, cut-outs are formed which define a gap 60 recessed in the segment 58 (see Figs. 3, 25). Through the gap 60, the first contact arm 34 projects from the inner side of the core conductive element 44 to contact the assigned ring element 6.3 which defines a floating ground contact element. In a respective way, the ring element 6.6 is contacted to the second contact arm 36 (see Fig. 2). However, the second contact arm 36 is directly contacted against an inner surface 62 of the core conductive element 44 and thus physically connected to the central ground path provided thereby to the define a male ground conductive element, while the first contact arm 34 is arranged with distance to the inner surface 62 by means of the dielectric sheet 42 and, hence, forms part of the floating ground conductive path rendering the ring 6.3 a floating ground male conductive element.

Accordingly, the floating ground ring 6.3 is assigned to ground by a capacitor, which will be described hereinafter by referring to Figs. 19 and 20. Fig. 19 essentially shows a perspective side of the proximal end of the first embodiment and depicts the central lead 26 circumferentially surrounded by the insulating cladding 22, which is adapted to press the segment 58 and the inner lead 30 against a rim of the sheet element 59 from an inner side. Between the proximal end of the segment 58 and the inner lead 30 there is provided the dielectric sheet 42, which supports the inner lead 30 such that a predetermined distance between an outer surface 40 of the inner lead 30 and the inner surface 62 of the segment 58 is realized. The two surfaces 62, 40 are arranged parallel to each other and with a slight distance. Accordingly, the inner surface 62 is a first capacity surface and the outer surface 40 of the inner lead 30 is the second capacity surface of the floating ground conductive path leading to a floating ground coupling capacity between the core conductive element 44 and the floating ground path to the floating ground ring 6.3 which is higher than a coupling capacity between the signal means 46.1 to 50.2 and the core conductive path formed by the core conductive element 44. As furthermore derivable from Figure 19, the conductive path leading to the first contact arm 34 is electrically and mechanically separate from the conductive path leading to the second contact arm 34 by cutting the proximal end section 32 of the inner lead 30 along a cutting line identified with reference numeral C in Figure 24 after the inner lead 30 has been placed within the core conductive element 44.

By interdisposing the dielectric sheet 42 between the segment 58 and the inner lead 30, all conductive paths provided by the inner lead 30 are electrically isolated from the core conductive element 44 made of sheet metal. Figures 9 to 11 depict a second embodiment of the core conductive element which is denoted with reference numeral 66. This core conductive element 66 is formed in a more rigid way than the core conductive element 44 made of bent and cut sheet metal. Specifically, the core conductive element 66 is provided with a central bore and with a solid tip 70 formed as a unitary part of the core conductive element. Between this tip 70 and a triangular end section 72 projecting through the organizing sleeve 14, there is provided a middle section 74 in which radial projections 76 are formed by cutting work (see Fig. 9). While the press fit between the radial projections 56 and the assigned male ground contact elements 6.6 is influenced by a certain elasticity of the core conductive element 44 due to the nature of the sheet metal material and by folding the triangular cross-section thereof and the minimum slot between the surface segments 58 (see Fig. 8), the press fit between respective male ground contact elements 6.3 and 6.6 is of different quality due to the rigid nature of the core conductive element 66. As can be derived from Fig. 9 and 10, the rings 6.3 and 6.6 are physically connected to the core conductive element 66 by press fitting. Accordingly, a floating ground male conductive element is omitted. However, the leads

46.1 to 50.2 are arranged as described above with reference to the first embodiment.

In the rear view according to Fig. 11 , the leads 46.1 to 50.2 are circumferentially spaced to one another and arranged essentially with a constant radius relative to the central axis of the core conductive element 66, and received within the guiding slots 52 of the organizing sleeve 14. The signal leads 46.1 and 46.2 define the conductive paths between a termination interface 78 for the leads 46.1 to 50.2 at the proximal end of the male rod 4 (see Fig. 10) and the respective rings 6 defining male signal contact elements. The leads 46.1 and

46.2 serve as respective conductive paths for a male differential pair 80 for the D interface for the USB 3.0 standard (see Fig. 11 in combination with Fig. 35). The leads 48.1 and 48.2 form the conductive paths from the termination interface 78 to the ring elements 6.4 and 6.5 forming a male differential pair for the TX interface 82 for the USB 3.0 standard. Finally, the signal leads 50.1 and 50.2 define the conductive paths from the termination interface 78 for the USB 3.0 standard to the rings 6.7 and 6.8 which define the male differential pair 80 for the RX interface of the USB 3.0 standard. The sleeve 12 according to the representation of Fig. 11 is force-fitted onto the radial projections 76 of the core conductive element 66 and thus physically connected to ground. In the same way, the rings 6.3 and 6.6 are directly connected to ground. As mentioned above, the tip is connected to ground by forming part of the core conductive element which defines a ground conductive path. Within the bore 68, the center pin 20 will be introduced for providing a power line. The core conductive element 66 may provide ground for this power line. Additionally, a tip element 10 may be introduced having a concentrical conductive element for the power line being electrically insulated against the core conductive element 66. Apart from those central conductive elements, the signal leads 46.1 to 50.2 are arranged in a non- concentrical way relative to the central axis of the male rod. They are also arranged non- concentrically relative to each other. Preferably the central ground element, i.e. the core conductive element 66, is arranged in a concentrical design. But it can be arranged also in a non-concentrical design. Thus, the core conductive element 66 defines with its poly- gon structure three outer edges 86.

Fig. 12 shows a further and third embodiment, in which the core conductive element 66 is a solid core conductive element as in the second embodiment (Figs. 9 to 11 ). However, this core conductive element 66 is provided with a circular cross-section throughout its entire length. The leads 46.1 , 46.2, 48.1 , 48.2, 50.1 and 50.2 are circumferentially spaced around the central axis as described with reference to the second embodiment. The principal arrangement of all leads 46 through 50 around the core conductive element 66 in the second and third embodiment will be described hereinafter by referring to Fig. 13.

In Fig. 13, the edges are denoted with reference numeral 86 and marked as full circles. Those full circles may either be formed by a single conductive element or by separate conductive elements which are arranged at the location of the position of the outer edges 86 in the scheme of Fig. 13 and formed by conductive element coupled to ground. Between neighboring edges 86, a connection line 88 has been inserted to define a triangle. Further, perpendicular lines 90 are introduced at a location where the intersection lines 88 intersect with each other, i.e. at the outer edge 86. Those perpendicular lines 90 extend perpendicular to the assigned connection lines 88. As can be seen from Fig. 13, the signal leads 46 are arranged between the perpendicular lines 90A, the signal leads 48 are arranged between the perpendicular lines 90B, and the signal leads 50 are arranged between the perpendicular lines 90C. In other words, each signal conductive path in longitudinal direction of the male rod 4 is shielded from the conductive paths assigned to another differential pair by the polygon constitution of the one or more ground conductive paths. Accordingly, electrical coupling between the conductive path to each differential pair is reduced to a great extent. While respective constitution of the polygon structure has been described by referring to a triangular polygon structure, the provisions likewise apply for a square, a pentagon or the like.

With those explanations, it is evident that the embodiment of Figure 12 has core ground conductive paths which are formed by lead elements 92 circumferentially spaced around the central axis, which will likewise provide the afore-discussed effect of eliminating coupling of conductive paths leading to different differential pairs to a great extend.

Figures 14 through 18 are to improve the understanding of the shell defined in the embodiment made by the ring element 6 and the washer element 8. As it can be seen from the schematic view of Figures 14 and 15, the washer element 8 has an outer circumferen- tial end section 94, which cooperates with neighboring ring elements 6 and an inner circumferential end section 96, which cooperates with the central conductive structure 54. In between those end sections 94, 96, there are provided multiple gaps 98, which are circumferentially spaced from one another to improve the impedance by reducing the overall material used for making the electrical plug and, furthermore, are used to guide therethrough individual signal leads 46 though 50 as shown in Figures 17 and 18.

As shown in Figure 4, the ring-shaped washer elements 8 have at their outer circumferential end section 94 a flange 100, which provides an outer circumferential supporting surface 102 radially inward of the outer circumferential surface of the male rod 4. The ring elements 6 are designed in a respective way and have a flange 104 at their both axial ends which defines an inner circumferential supporting surface 106 radially outward of the inner circumferential surface of the rings 6 which is to cooperate with the outer circumferential supporting surface 102 of the assigned washer element 8. The flanges 100, 104 each have a length of approximately between 0.1 mm and 0.2 mm, here 0.15 ± 0.05. The flanges are selected to be as thin as possible for reducing impedance. The washer elements 8 are positioned relative to the central contact structure 54 in a positive fit by bosses 108, which are shown in Figures 25 and 26. Those bosses are arranged on the three straight surface segments of the triangular core conductive element 44. Each surface segment has a row of bosses 108 provided with a relative distance to each other in axial direction of the male rod 4 corresponding to the thickness of the washer elements 8. Those bosses 108 are formed by press-working of the sheet metal forming the core conductive element 44. Further, by press-working, each surface segment at the distal end thereof is provided with a snap arm 110, which is elastically bendable about an axis lying within the plane of the respective surface segment and extending perpendicular to the main axis of the male rod 4. At the proximal end of the core conductive element 44, the same is provided with plural projecting tongues 112, which are cut out from the sheet metal. The function of the projecting tongues 112 will be described hereinafter with respect to the assembly method.

First, the core conductive element 44 is prepared by cutting and bending a sheet metal piece to provide the core conductive element as depicted in Figures 25 and 26. Next, the inner lead 30, which has previously been cut and bent by metal working to assume the shape depicted in Figure 24 is provided with the dielectric sheet 42. This dielectric sheet 42 is provided with adhesive material. Accordingly, the dielectric sheet is glued on the outer surface 40 of the inner lead 30 as shown in Figure 24. The inner lead 30 is then introduced into the core conductive element from the proximal side thereof.

The organizing sleeve 14 preassembled with the signal leads 46 - 50 as depicted in Fig- ure 23 is then shifted over the core conductive element 44 from the distal end thereof until the organizing sleeve contacts the projection tongues of the core conductive element (cp. Figure 27).

Then, the elements forming the male contact elements on the outer circumferential surface of the male rod 4 are stacked upon each other in an alternating way and shifted over the core conductive element 44 and the signal leads 46-50. The sleeve 12 is placed against the projection tongues 112 of the central conductive element 44 and furthermore abuts the radial stops 15 of the organizing sleeve 14. When sliding the leads 46-50 relative to the elements forming the shell of the male rod 4, and in particular through the assigned gaps 18 of the washers 8, the inwardly bent forward end of each lead 46-50 will facilitate assembly of the shell.

After the entire shell has been placed surrounding the core conductive element 44, the core conductive element is radially expanded. For this, a tooling pin is inserted into the core conductive element 44. This tooling pin cooperates with the surface segments and urges the same in a radial outward direction. The corners of the triangular core conductive element remain essential unchanged in their position and dimension. Prior to insertion of the tooling pin, the core conductive element is arranged within the washer elements 8 as depicted in Figure 28. From the initial position, the first and second contact arms 34, 36 are projecting the inner surface 38 of the inner lead 30 prior to insertion of the tooling pin. The tooling pin is inserted from the proximal end of the core conductive element. Accordingly, the tooling pin not only expands the core conductive element 44, but also pushes the first and second contact arms 34, 36 radially outward to contact the assigned male ground contact element 6.3 and 6.6. After the tooling pin has been pushed through the entire core conductive element for expanding the same, the tooling pin is retracted. At the same time, the center pin 20 is introduced and assumes the space which is left by the retraction of the tooling pin. Both, the tooling pin and the center pin are simultaneously moved such that elastic stresses contained in the core conductive element 44 after expansion thereof are secured by material within the core conductive element being either provided by the tooling pin or by the center pin 20.

As in particular derivable from Figure 20, the insulating cladding 22 is provided with a contact arm receiving groove 113, which receives proximal end sections of the first and sec- ond contact arms 34, 36, respectively. By contact of those proximal ends of the first and second contact arms 34, 36, respective arms 34, 36 are securely pressed against the inner circumference of the assigned ring elements 6.3, 6.6, respectively.

The center pin 20 has near its distal end three cut-outs adopted to receive each of the three snap arms 110 as the same flex about their axis. At a position, in which those cut outs are positioned underneath the snap arms 110, the movement of the tooling pin and the center pin 20, respectively is halted. From the distal end, the tip element 10 is pushed over the center pin 20 to secure the tip element 10 by positive locking with means, which will be described hereinafter by referring to Figure 21.

The tip element 10 has a central bore 114 which is adapted to receive the center pin 20 and is provided with a radial groove 116 being open to said bore 114. The groove 116 is delimited by a proximal rim 118, which can be chamfered to provide a funnel-shaped entrance to the bore 114. The snap arms 110 each are provided with a hammer-headed end 120, which fit into the groove 116 and are separated from spring arms 122 of the snap arms 110 by recesses 124, which are adapted to receive the proximal rim 118. When axially moving the tip element 10 towards the distal end of the snap arms 110, the same are urged inwardly by the chamfered free ends of the snap arm 110. When reaching the groove 116, the spring arms 122 flex back such that the hammer-headed ends 120 are urged into the groove 116. After this snapping movement is completed, the central pin 20 is advanced further into the core conductive element 44, while simultaneously retracting the tooling pin. Accordingly, the cut-outs provided at the outer circumferential surface of the center pin 20 are shifted inwardly. The regular outer circumferential surface of the center pin 20 abuts against the snap arms 110. Accordingly, the snap arms 110 cannot flex radially inwardly. Thus, the positive fit between the core conductive element and the tip element 10 by means of the snap arm 110 and the proximal rim 118 is secured. After insertion of the center pin 20, the inner lead 30 is sandwiched between the central pin 20 and the surface segment 58 of the core conductive element 44 with the dielectric sheet 42 therebetween. Accordingly, the inner lead 30 is securely held relative to the core conductive element 44. Then, the proximal end section 32 of the inner lead 30 is cut to separate the first contact arm 34 from the second contact arm 36, to render the first con- tact arm a contact for a floating ID, while rendering the second contact arm 36 a contact element permanently connecting the assigned ring element 6.6 to ground.

Prior to expansion of the core conductive elements 44, the washer elements 8 are axially shifted to assume a predetermined position for proper positioning in particular of the assigned ring elements 6. This shifting is achieved by handling the washer elements 8 from the outer circumference thereof. Clamping means C are schematically shown in Figures 28 and 29 for achieving this axial shifting of the washer elements 8. For such shifting, a specific tool is used, which clamps the washer elements 8 with clamping means individually movable and controllable to bring the same in the predetermined position.

Cables are connected at the termination interface 78. The first contact arm 34 is assigned to a floating ID, while the second contact arm 36 is constantly connected to ground. As evident e.g. from Fig. 3, the proximal, i.e. terminal ends of all signal leads 46 lie within a single termination plane 126. Between this termination plane and the sleeve 12 and the organizing sleeve 14, the projecting tongues 112 protrude in radial direction which abut an end face of the sleeve 14, thereby physically coupling the same to ground. At least one of those projecting tongues 112 can be used as a termination and for coupling the core conductive element to ground. The projection tongues 112 likewise define an abutment for the organizing sleeve 16 when being mounted on the core conductive element 44. Further, the projecting tongues 112 prevent extraction of the male rod 4 or parts thereof through the sleeve 12 during use of the plug, which sleeve 12 is secured to a housing 128 (see Figure 22) of the electrical plug usually by injection molding. This housing 128 can be rather compact as only the proximal end section 28 of the central lead 26 and the proximal end section 32 of the inner lead 30 project the termination plane 126 to the proximal side thereof.

Figure 22 shows an alternative embodiment in which the male rod 4 is radially projected by a rib section 130. Neighboring to said rib section 130 in circumferential direction, the afore-described sequence of ring elements 6 and washer elements 8 is maintained (not shown). The rib section 130 has on its radial end face 132 two optical interfaces 134. The embodiment of an electrical plug 2 depicted in Fig. 22 is provided with the aforementioned jack housing 128.

Figures 30 and 31 are to embody an example for an electrical jack 140, which has a jack housing 142 defining at its distal end a receptacle 144 and supporting in an isolated manner multiple female contact elements 146 assigned to respective male contact elements 6 of the afore-described electrical plug 2. Both female contact elements 146 are arranged within the jack housing 142 in a well-known method. Each female contact element 146 is formed by cutting and bending of a sheet metal and is inserted into openings of the injec- tion-molded jack housing 142. All termination ends 148 of the female contact elements 146 are exposed to a supporting surface 150 of the jack housing 142 for surface mounting of the electrical jack 140.

As in particular evident from Fig. 31 , the electrical jack 140 is provided with a front contact element 152 which has a termination end 154 exposed to the supporting surface 150 de- fining a power interface. The front contact element is provided to cooperate with the central lead 26 of the electrical plug 2. Further, the jack housing 142 secures a clamping spring 156, which cooperates with an outer circumferential groove provided by the tip element 20 for securing the electrical plug 2 in the housing 142 of the electric jack 140 if the male rod 4 is inserted into the receptacle 144. The jack housing 142 can be provided with a housing slot 158 which is exemplified in Figs. 32 to 34 for reducing impedance. In the Example of Figs. 32 and 33, said housing slot 158 is defined as a groove which is open to the receptacle 144 in radial direction and recessed within the material forming the jack housing 142. This housing slot 158 is provided at an axial location corresponding to the position of a high speed data pair of a male rod 4 being inserted into the receptacle 144. The slot can e.g. be provided at a location of the contact elements 6.4, 6.5 and/or 6.7, 6.8. Within the housing slot 158, the assigned female elements are exposed to make contact with the respective male contact elements 8.4, 8.5 or 8.7, 8.8. To attain the aforementioned effect of reducing impedance, the housing slot 158 does not necessarily have to extend over an angle of 360° as shown. Instead, multiple housing slots 158 can be provided which extend at least in axial direction of the receptacle 154.

Figure 35 shows an electrical jack and an electrical plug system in which the male rod 4 is inserted into the receptacle 144. Proper alignment between the male contact elements 6 of the male rod 4 and the female contact elements 146 exposed within the receptacle 144 is attained by a reference surface 160 defined by the jack housing 142, which reference surface 160 cooperates with a surface provided by the machined tip element 10. Accordingly, a mounting gap can be provided between the jack housing 142 and the sleeve flange 16 or the plug housing 128. This mounting gap is identified with reference numeral 162 in Figure 35 and allows covering of the jack housing 142 by a cover of the producer of a communication device transmitting serial data, which receives the electrical jack 140 as a standard part. In addition to this mounting gap 162 providing the additional length in particular of a distal section of the sleeve 12 forming part of the male rod 4, the jack housing 142 can be partially taken away provided that the first female contact elements 146.1 , 146.3 are arranged adjacent to each other on one specific side of the receptacle 144 as exemplified in Figure 35. On top of Figure 35, the positions of the interfaces are countered from the entrance of the receptacle 144. The first and second positions are assumed by the D interface of the USB 3.0 standard. This first differential pair for D is sandwiched between ground provided by the sleeve 12 and the ground conductive ring element 6.3 provided at the third position and defining an ID. Distal thereof, i.e. on the fourth and the fifth position, a differential pair for the TX interface conforming to the USB 3.0 standard is provided. This differential pair 82 is arranged between the male contact element 6.3 and contact element 6.6 assigned to ground. Distal of the ring element 6.6 and on the seventh and eighth position, the RX in- terface conforming with the USB 3.0 standard is provided. Again, this differential pair is arranged between the ground defined by the ring element 6.6 and the ground provided by the tip element 10. For reducing cross talk between the high-speed paths, i.e. in particular the pairs for TX and RX, the female contacts thereof are arranged at a position diametri- cally to each other. Accordingly, the RX female contact elements 146.7, 146.8 are arranged on the lower side as can be seen in Figure 35. The same holds true for the female contact elements 146.1 , 146.2. However, the female contact elements 146.4, 146.5 are arranged on the upper side as shown in Figure 35, i.e. diametrical to the D pair and the RX pair, respectively. Such measure has proven to reduce the cross talk in particular be- tween TX and RX.

Finally, Figure 36 shows an embodiment of an electrical jack 140 adapted to cooperate with the plug shown in Figure 22. In this embodiment, the jack housing 142 is provided with an axial slot 164, which is open to the receptacle 144 and adapted to receive the rib section 130 of the embodiment of Figure 22. Accordingly, a radial end face 166 of said axial slot 164 is provided with an optical interface 168, which can optically be connected to the optical interface 134 of the plug shown in Figure 22. All other elements of this embodiment of an electrical jack 140 of Figure 36 are identical to those previously described. Accordingly, the reference signs are also used for identifying identical elements.

Reference signs

2 Electrical plug

4 male rod

6 ring element

6.1 male contact element for D interface

6.2 male contact element for D interface

6.3 male contact element for ID

6.4 male contact element for TX interface

6.5 male contact element for TX interface

6.6 male contact element for ground

6.7 male contact element for RX interface

6.8 male contact element for RX interface

8 washer element

10 tip element

12 sleeve

13 cylinder section

14 organizing sleeve

15 radial stop

16 sleeve flange

18 sleeve flange

20 center pin

22 insulating cladding

24 male front contact element

26 central lead

28 proximal end section of central lead

30 inner lead

32 proximal end section of inner lead

34 first contact arm

36 second contact arm

38 inner surface

40 outer surface

42 dielectric sheet

44 core conductive element made of sheet metal 46.1 signal lead D+

46.2 signal lead D-

48.1 signal lead SSTX+

48.2 signal lead SSTX- 50.1 signal lead SSRX+

50.2 signal lead SSRX-

52 guiding slots

54 central contact structure

56 radial projection

58 segment

59 sheet element

60 gap

62 inner surface of core conductive element

64 outer surface of core conductive element 66 core conductive element (solid embodiment)

68 bore

70 tip

72 triangular end section

74 middle portion

76 radial projection

78 termination interface

80 male differential pair for D

82 male differential pair for TX

84 male differential pair for RX

86 outer edge

88 connection line

90 perpendicular line

92.1 ground lead

92.2 ground lead

92.3 ground lead

94 outer circumferential end section

96 inner circumferential end section

98 gap

100 flange 102 outer circumferential supporting surface

104 flange

106 inner circumferential supporting surface

108 boss

110 snap arm

112 projecting tongue

113 contact arm receiving groove

114 central bore

116 groove

118 proximal rim

120 hammer headed end

122 spring arm

124 recess

126 termination plain

128 plug housing

130 rib section

132 radial end face

134 optical interface

140 electrical jack

142 jack housing

144 receptacle

146 female contact element

146.1 female contact element for D interface

146.2 female contact element for D interface

146.3 female contact element for ID and floating ground

146.4 female contact element for TX interface

146.5 female contact element for TX interface

146.6 female contact element for ground

146.7 female contact element for RX interface

146.8 female contact element for RX interface

146.9 female contact element for ground

148 termination end

150 supporting surface

152 female front contact element termination end of front contact element spring

housing slot

reference surface

mounting gap

axial slot

radial end

optical interface

Cutting line

Claims

Patent Claims

1. An electrical plug (2) with a plug housing (128), a male rod (4) having multiple male contact elements (6) arranged spaced from one another on an outer surface thereof, at least one insulation member (8) interdisposed between neighboring male contact elements (6) and a central conductive structure (54) comprising conductive paths (26, 30, 44, 46, 48, 50), whereby at least some of the conductive paths being electrically connected to an assigned male contact element (6, 24),

characterized in that

at least some conductive paths (30, 46, 48, 50) are formed by leads, which are non- concentrically arranged when seen in cross sectional direction of the male rod (4).

2. The electrical plug (2) according to claim 1 , characterized in that the leads (46-50) forming the conductive paths of the central conductive structure (54) are non- concentrically arranged relative to each other.

3. The electrical plug (2) according to claim 1 or 2, characterized by signal leads (46- 50) electrically connected to assigned male contact elements (6.1 ,6.2,6.4, 6.5, 6.7, 6.8) defining male signal contact elements and spaced from one another in circumferential direction of the male rod (4).

4. The electrical plug (2) according to any of the preceding claims, characterized in that the signal leads (46-50) are arranged spaced from and around a core conductive element (44, 66).

5. The electrical plug (2) according to any of the preceding claims, characterized by an inner lead (30) arranged within the core conductive element (44).

6. The electrical plug (2) according to any of the preceding claims, characterized by a central lead (26) held within the core conductive element (44, 66) in an insulated fashion.

7. The electrical plug (2) according to any of the preceding claims, characterized in that a proximal end of the signal leads (46-50) defines a termination interface (78) and that the termination interface (78) of plural signal leads (46-50) are arranged in one plane (126).

8. The electrical plug (2) according to any of the preceding claims, characterized in that the male contact elements are formed by ring elements (6) and that the insulation member is formed by a ring-shaped washer (8) element, an outer circumferential end section (94) thereof cooperating with the neighboring ring elements (6) and an inner circumferential end section (96) thereof cooperating with a core element (54) extending in axial direction of the male rod (4).

9. The electrical plug (2) according to claim 8, characterized in that an axial end section of the washer element (8) and/or an axial end section of the ring element (6) is provided with a flange (100, 104), which cooperates with an inner circumferential surface (96) of a neighboring ring element (6) and/or an outer circumferential surface (102) of a neighboring washer element (8), respectively.

10. The electrical plug (2) according to claims 8 or 9, characterized in that the washer element (8) is provided with gaps (98) arranged between the inner circumferential end section (96) and the outer circumferential end section (94), and that the gaps (98) are circumferentially spaced from one another.

11. The electrical plug (2) according to any of the claims 8 to 10, characterized in that the washer element (8) is secured against the core element (54) in axial direction by means of a positive fit.

12. The electrical plug (2) according to any of the proceeding claims, characterized in that a core element (44) is formed of sheet metal cut and bent to provide, at a free end thereof, at least one snap arm (110) having positive locking means (120) and that a tip element (10) of the male rod (4) has an engaging section (116) which is adapted to cooperate with the positive locking means (120) of the snap arm (110) to provide a positive fit between the core element (44) and the tip element (10).

13. The electrical plug (2) according to claim 12, characterized by a blocking element (20) received within the core element (44) cooperating with the snap arm (110) to secure the positive fit between the core element (44) and the tip element (10).

14. The electrical plug (2) according to any of the preceding claims, characterized in that, at a proximal end of the male rod (4), a sleeve is provided defining a sleeve male ground contact element assigned to ground.

15. The electrical plug (2) according to any of the preceding claims, characterized in that the sleeve (14) is connected to a cable braid of a cable connected to the plug housing (128).

16. The electrical plug (2) according to any of the preceding claims, characterized in that two neighboring male contact elements define a male differential pair (80, 82, 84) and that a male ground contact element (6.3, 6.6, 10) assigned to ground is arranged between two male differential pairs (80, 82, 84). 7. The electrical plug (2) according to any of the preceding claims, characterized in that a sleeve male ground contact element (12) and/or a male ground contact element (6.3, 6.6) is assigned to ground by means of a capacitor.

18. The electrical plug (2) according to claim 17, characterized in that a core element (44) defines a core conductive element (44) providing a core ground conductive path electrically connected to at least one male contact element (6.6, 10), that the core conductive element (44) defines a first capacity surface (62), that an inner lead is arranged radially inward of the first capacity surface (62) and defines a second capacity surface (64) of a floating ground conductive path, that the first and the second capacity surfaces (62, 64) form a larger floating ground coupling capacity between the core conductive element (44) and the floating ground conductive path than a coupling capacity between signal leads (46-50) and the core ground conductive path.

19. The electrical plug (2) according to claim 18, characterized in that a core conductive element (44) comprises sheet metal defining a polygon structure with a gap (16) extending in axial direction of the male rod (4) and that the inner lead (30) is arranged within the polygonal structure and coupled to a male ground contact element via a contact arm (34) extending through the gap (60).

20. The electrical plug (2) according to claim 18 or 19, characterized in that a dielectric sheet (42) is provided between the first capacity surface (62) and the second capacity surface (64), covers at least one of the two capacity surfaces (62, 64) and is made of an insulating material.

21. The electrical plug (2) according to any of the preceding claims, characterized in that the central contact structure (54) comprises at least one core conductive element (44; 66; 92.1 , 92.2., 92.3) electrically connected to at least one male contact element (6) defining a ground contact element (6.3, 6.6) and that the at least one core conductive element (44; 66; 92.1, 92.2., 92.3), when seen in cross sectional direction of the male rod (4), define outer edges (86) of a polygon structure.

22. The electrical plug (2) according to claim 21 , characterized in that signal leads (46- 50) electrically connected to male contact elements (6) defining male signal contact elements (6.1 , 6.2, 6.4, 6.5, 6.7, 6.8) are only arranged between parallel lines (90) intersecting with neighboring edges (86) of the polygon structure and extending perpendicular to a connection line (88) connecting the neighboring edges (86), when seen in cross-sectional direction of the male rod (4).

23. The electrical plug (2) according to claim 21 or 22, characterized by a core ground contact element (66) defining the outer edges of the polygon structure, wherein the at least one male ground contact element, formed by a ring (6.3, 6.6), is force-fitted onto radial projections (56, 76) of the core ground element (44, 66).

24. The electrical plug (2) according to claim 23, characterized in that the core ground element (44, 66) has a polygonal, preferably a triangular cross-sectional shape.

25. The electrical plug (2) according to any of the preceding claims, characterized in that the male rod (4) comprises a rib section (130), projecting an essentially cylindrical surface section of the male rod (4) and exposing on its radial end face (132) the optical interface (134).

26. The electrical plug (2) according to any of the preceding claims, characterized by an optical transceiver, the input side thereof being connected to a fibre optical element, the output side thereof being electrically connected to at least one of the male contact elements (6) and being arranged within the plug housing.

27. The electrical plug (2) according to any of the preceding claims, characterized by a wireless transceiver, the input side thereof defining a wireless interface and the output side thereof being electrically connected to at least one of the male contact ele- ments (6).

28. An electrical jack (140) for an electrical plug according to any of claims 1 to 27, with a male rod having multiple male contact elements arranged spaced from one another on an outer surface thereof, with at least one insulation member interdisposed between neighboring male contact elements and with a central conductive structure comprising conductive paths, each of which being electrically connected to an assigned male contact element, having a jack housing (142) defining a receptacle (144) and holding multiple female contact elements (146) exposed within the receptacle (144) and arranged therein to contact assigned predetermined male electrical contact elements (6) when the male rod (4) of the electrical plug (2) is inserted into the receptacle ( 1 4) ,

characterized by,

at least eight female contact elements (146) adopted to cooperate with male contact elements (6) arranged on the outer circumferential surface of the male rod (4).

29. The electrical jack (140) as defined in claim 28, characterized in that the first, the third, the sixth and the ninth female contact element from an entrance opening of the receptacle are positioned such that those female contact elements are adopted to contact the first (ground or Mic), the second (ground or Mic), the third (right audio) and the top (left audio) male contact elements arranged on the outer circumferential surface of a 3.5 mm plug according to AV JEITA Standard. 30. The electrical jack (140) according to claim 28 or 29, characterized in that, at a location of a female contact element (146) defining a female high speed data contact, the jack housing (142) has at least one slot (158).

31. The electrical jack (140) according to claim 30, characterized in that at least two female high speed data elements (146) are arranged adjacent to each other in axial direction of the receptacle (145) to define a high speed data pair and that the slot

(158) extends over the at least two female high speed contact elements (146)

32. The electrical jack (140), according to any of the claims 28 to 31 , characterized in that at least two female data differential pairs defined by neighboring female contact elements, wherein the first female data differential pair and the second female data differential pair are arranged adjacent to each other and wherein the female contact elements of the first female data differential pair are provided diametrically of the female contact elements of the second female data differential pair.

The electrical jack (140) according to any of claims 28 to 32, characterized in that ' the jack housing has an axial slot (164) open to the receptacle (144) and to an entrance opening thereof and that a radial end face (166) of said radial slot (164) is provided with an optical interface (168).

A jack and plug system comprising:

- an electrical plug as defined in any of claims 1 to 27,

- an electrical jack as defined in any of claims 28 to 33,

characterized in that

the jack housing (142) and the male rod (4) are designed such that, when the male rod (4) is inserted into the receptacle (144), a reference surface (166) of the jack housing (142) cooperates with a distal end section (10) of the male rod (4).

The jack and plug system as defined in claim 34, characterized by defining a USB 3.0 interface in

that the male rod (4) has at least eight male contact elements (6) arranged on the outer circumferential surface thereof,

that the jack has at least eight female contact elements (146) adopted to cooperate with the at least eight male contact elements (6) arranged on the outer circumferential surface of the male rod (4),

that a male front contact element (24) is provided at the free end of the male rod adopted to cooperate with a mating front female contact element (152) arranged at the inner end of the receptacle (144), and

that the outer dimension of the plug essentially corresponds with that of a 3.5 mm plug according to AV JEITA Standard.

The jack and plug system as defined in claim 34 or 35, characterized in that the front contact elements (24; 152) provide a power interface.

An electrical cable assembly for serial digital communication characterized by an electrical plug according to any of the claims 1 - 27 or an electrical jack according to any of the claims 28 to 33 connected to a cable and at least some of the contact elements are provided as one or more differential pairs, wherein each differential pair is connected to a pair within the cable.

38. An electrical device, characterized by a plug for data transmission according to any of the claims 1 - 27 or an electrical jack according to any of the claims 28 to 33, wherein at least some of the contact elements are provided as one or more differential pairs, which are connected to a serial communication interface and configured to transmit or receive serial data.

39. A method of producing an electrical plug according to any of claims 1 to 27, comprising the steps of:

- preassembling a central conductive structure (54) of the male rod (4),

- preparing multiple washer elements (8) and multiple ring elements (6) and arranging the washer elements(8) and the ring elements (6) coaxially to the axis of the male rod (4) in an alternating manner,

and shifting the washer elements (8) in axial direction relative to each other to as- sume a predetermined position,

- inserting the central conductive structure (54) into the washer elements (8) and the ring elements (6), to assume the final position in which the lead elements (46- 50) of the central contact structure (54) can contact the assigned ring elements (6),

- securing the central conductive structure (54) to the washer elements (8) and the ring elements (6), and

- providing the housing on a terminal end of the central conductive structure.

40. The method as defined in claim 39, characterized in that the central conductive structure (54) is secured to the washer elements (8) by radially expanding the central contact structure (54). 41. The method as defined in claim 39 or 40, characterized in that bosses (108) provided on the outer circumferential surface of a core conductive element (44) of the central conductive structure (54) are urged between the washer elements (8) to position the washer elements (8) in axial direction by means of a positive fit.

42. The method as defined in any of claims 39 to 41 , characterized in that central con- ductive structure (54) is radially expanded by a tooling pin inserted into the central conductive structure (54) and that a center pin (20) is introduced into the central conductive structure (54) from another end simultaneously with the extraction of the tooling pin.

43. The method as defined in claim 42, characterized in

that the center pin (20) is introduced into the core conductive element (44) to an intermediate position in which at least one snap arm (110) of core conductive element (44) is level with a cut-out provided on the outer circumference of the center pin (20),

that a tip element (10) is snapped onto the snap arm (110) as the center pin (20) is held in the intermediate position, and

that the center pin (20) is further introduced into the core conductive element (44) to assume a final position.

44. The method as defined in any of claims 39 to 43, characterized in that at least one ring element (6.3, 6.6) is electrically connected to a contact arm (30, 38) of an inner lead (30) being arranged within the preassembled central conductive structure (54) by radially pushing the contact arm (34, 36) against the assigned ring element (6.3, 6.6) after the central conductive structure (54) has been inserted into the washer elements (8).