The invention generally relates to an electrical connection system, and more particularly relates to an electrical connection system designed to connect shielded wire cables capable of differentially transmitting digital electrical signals having a data transfer rate of 5 Gigabits per second (Gb/s) or higher further requiring frequency content to 7.5 Gigahertz (GHz).
The increase in digital data processor speeds has led to an increase in data transfer speeds. Transmission media used to connect electronic components to the digital data processors must be constructed to efficiently transmit the high speed digital signals between the various components. Wired media, such as fiber optic cable, coaxial cable, or twisted pair cable may be suitable in applications where the components being connected are in fixed locations and are relatively close proximity, e.g. separated by less than 100 meters. Fiber optic cable provides a transmission medium that can support data rates of up to nearly 100 Gb/s and is practically immune to electromagnetic interference. Coaxial cable typically supports data transfer rates up to 100 Megabits per second (Mb/s) and has good immunity to electromagnetic interference. Twisted pair cable can support data rates of up to about 5 Gb/s, although these cables typically require multiple twisted pairs within the cable dedicated to transmit or receive lines. The conductors of the twisted pair cables offer good resistance to electromagnetic interference which can be improved by including shielding for the twisted pairs within the cable.
Data transfer protocols such as Universal Serial Bus (USB) 3.0 and High Definition Multimedia Interface (HDMI) 1.4 require data transfer rates at or above 5 Gb/s. Existing coaxial cable cannot economically or reliably be implemented to support data rates near this speed. Both fiber optic and twisted pair cables are capable of transmitting data at these transfer rates, however fiber optic cables are significantly more expensive than twisted pair, making them less attractive for cost sensitive applications that do not require the high data transfer rates and electromagnetic interference immunity.
Infotainment systems and other electronic systems in automobiles and trucks are beginning to require cables capable of carrying high data rate signals. Automotive grade cables must not only be able to meet environmental requirements (e.g. thermal and moisture resistance), they must also be flexible enough to be routed in a vehicle wiring harness and have a low mass to help meet vehicle fuel economy requirements. Therefore, there is a need for a wire cable with a high data transfer rate that has low mass and is flexible enough to be packaged within a vehicle wiring harness, while meeting cost targets that cannot currently be met by fiber optic cable. Although the particular application given for this wire cable is automotive, such a wire cable would also likely find other applications, such as aerospace, maritime, industrial control, or other data communications.
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
In accordance with one embodiment of this invention, an electrical connection system is provided. The electrical connection system includes a first shielded cable having a first electrical conductor and a second electrical conductor surrounded by a first shield conductor which is surrounded by a first insulating jacket, a second shielded cable having a third electrical conductor and a fourth electrical conductor surrounded by a second shield conductor which is surrounded by a second insulating jacket, a plug connector having a first plug terminal a second plug terminal, and a receptacle connector configured to mate with said plug connector having a first receptacle terminal and a second receptacle terminal configured to receive the first and second plug terminals respectively. The electrical connection system further includes a plug shield longitudinally surrounding the plug connector and electrically isolated from the plug terminals having an upper plug shield and a lower plug shield. The lower plug shield is attached to the first shield conductor by a first pair of shield crimp wings. An extremity of the first pair of shield crimp wings is collocated with an extremity of the first shield conductor. The electrical connection system additionally includes a receptacle shield longitudinally surrounding the receptacle connector and electrically isolated from the receptacle terminals having an upper receptacle shield and a lower receptacle shield. The lower receptacle shield is attached to the second shield conductor by a second pair of shield crimp wings. An extremity of the second pair of shield crimp wings is collocated with an extremity of the second shield conductor.
The extremity of the first pair of shield crimp wings may be in a range of 1.0 to 1.5 millimeters from the first and second attachment points and the extremity of the second pair of shield crimp wings may be in a range of 1.0 to 1.5 millimeters from the third and fourth attachment points.
The lower plug shield may be attached to the first insulating jacket by a first pair of jacket crimp wings and the lower plug shield may be attached to the upper plug shield by a first shield attaching feature located intermediate the first pair of shield crimp wings and the first pair of jacket crimp wings. The lower receptacle shield may be attached to the second insulating jacket by a second pair of jacket crimp wings and the lower receptacle shield may be attached to the upper receptacle shield by a second shield attaching feature located intermediate the second pair of shield crimp wings and the second pair of jacket crimp wings.
The upper plug shield may define a first tab in direct and compressive contact with the first pair of shield crimp wings of the lower plug shield and the upper receptacle shield may defines a second tab in direct and compressive contact with the second pair of shield crimp wings of the lower receptacle shield. Alternately or in addition, the upper plug shield may define a first pair of opposed tabs in direct and compressive contact with the first pair of shield crimp wings of the lower plug shield and the upper receptacle shield may define a second pair of opposed tabs in direct and compressive contact with the second pair of shield crimp wings of the lower receptacle shield.
The receptacle shield may be configured to slideably engage the interior of the plug shield. The extremity of the first pair of shield crimp wings may be substantially flush with the extremity of the first shield conductor and the extremity of the second pair of shield crimp wings may be substantially flush with the extremity of the second shield conductor
The first plug terminal may include a planar first connection portion that is characterized by a generally rectangular cross section and a first attachment portion attached to the first electrical conductor. The second plug terminal may also include a planar second connection portion that is characterized by a generally rectangular cross section and a second attachment portion attached to the second electrical conductor. The first and second plug terminals may form a first mirrored terminal pair having bilateral symmetry about a longitudinal axis. The first receptacle terminal may include a third attachment portion attached to the third electrical conductor and a first cantilever beam portion that is characterized by a generally rectangular cross section defining a convex first contact point depending from the first cantilever beam portion. The first contact point is configured to contact the first connection portion of the first plug terminal. The second receptacle terminal may include a fourth attachment portion attached to the fourth electrical conductor and have a second cantilever beam portion that is characterized by a generally rectangular cross section defining a convex second contact point depending from the second cantilever beam portion. The second contact point is configured to contact the second connection portion of the second plug terminal. The first and second receptacle terminals may form a second mirrored terminal pair having bilateral symmetry about the longitudinal axis. When the plug connector is connected to the receptacle connector, the major width of the first connection portion may be substantially perpendicular to the major width of the first cantilever beam portion and the major width of the second connection portion may be substantially perpendicular to the major width of the second cantilever beam portion.
Further features and advantages of the invention will appear more clearly on a reading of the following detailed description of the preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
Presented herein is an electrical connector assembly for a shielded wire cable assembly that is capable of carrying digital signals at rates up to 5 Gigabits per second (Gb/s) (5 billion bits per second) to support both USB 3.0 and HDMI 1.4 performance specifications. The wire cable assembly includes a wire cable having a pair of conductors (wire pair) and a conductive sheet and braided conductor to isolate the wire pair from electromagnetic interference and determine the characteristic impedance of the cable. The wire pair is encased within dielectric belting that helps to provide a consistent radial distance between the wire pair and the shield. The belting may also help to maintain a consistent twist angle between the wire pair if they are twisted. The consistent radial distance between the wire pair and the shield and the consistent twist angle provides a wire cable with more consistent impedance. The wire cable assembly may also include an electrical receptacle connector having a mirrored pair of plug terminals connected to the wire pair and/or an electrical plug connector having a mirrored pair of receptacle terminals connected to the wire pair that is configured to mate with the plug terminals of the plug connector. The receptacle and plug terminals each have a generally rectangular cross section and when the first and second electrical connectors are mated, the major widths of the receptacle terminals are substantially perpendicular to the major widths of the plug terminals and the contact points between the receptacle and plug terminals are external to the receptacle and plug terminals. Both the receptacle and plug connectors include a shield that longitudinally surrounds the receptacle or plug terminals and is connected to the braided conductor of the wire cable. The wire cable assembly may also include an insulative connector body that contains the receptacle or plug terminals and shield.
The central pair of first and second conductors 102, 104 may be longitudinally twisted over a lay length L, for example once every 15.24 mm. Twisting the first and second conductors 102, 104 provides the benefit of reducing low frequency electromagnetic interference of the signal carried by the central pair. However, the inventors have discovered that satisfactory signal transmission performance may also be provided by a wire cable wherein the first and second conductors 102, 104 are not twisted about one about the other. Not twisting the first and second conductors 102, 104 may provide the benefit of reducing manufacturing cost of the wire cable by eliminating the twisting process. Not twisting the first and second conductors 102, 104 results in reduced differential insertion loss but has the disadvantage of requiring specific limitations in vehicle routing, specifically to non-uniform bending along the length of the cable run.
Each of the first and second conductors 102, 104 are enclosed within a respective first dielectric insulator and a second dielectric insulator, hereafter referred to as the first and second insulators 108, 110. The first and second insulators 108, 110 are bonded together. The first and second insulators 108, 110 run the entire length of the wire cable 100, except for portions that are removed at the extremities of the cable in order to terminate the wire cable 100. The first and second insulators 108, 110 are formed of a flexible dielectric material, such as polypropylene. The first and second insulators 108, 110 may be characterized as having a thickness of about 0.85 mm.
Bonding the first insulator 108 to the second insulators 110 helps to maintain a consistent spacing S between the first and second conductors 102, 104. The methods required to manufacture a pair of conductors with bonded insulators are well known to those skilled in the art.
The first and second conductors 102, 104 and the first and second insulators 108, 110 are completely enclosed within a third dielectric insulator, hereafter referred to as the belting 112, except for portions that are removed at the extremities of the cable in order to terminate the wire cable 100. The first and second insulators 108, 110 and the belting 112 together form a dielectric structure 113.
The belting 112 is formed of a flexible dielectric material, such as polyethylene. As illustrated in
The belting 112 is completely enclosed within a conductive sheet, hereafter referred to as the inner shield 116, except for portions that may be removed at the extremities of the cable in order to terminate the wire cable 100. The inner shield 116 is longitudinally wrapped in a single layer about the belting 112, so that it forms a single seam 118 that runs generally parallel to the central pair of first and second conductors 102, 104. The inner shield 116 is not spirally wrapped or helically wrapped about the belting 112. The seam edges of the inner shield 116 may overlap, so that the inner shield 116 covers at least 100 percent of an outer surface of the belting 112. The inner shield 116 is formed of a flexible conductive material, such as aluminized biaxially oriented PET film. Biaxially oriented polyethylene terephthalate film is commonly known by the trade name MYLAR and the aluminized biaxially oriented PET film will hereafter be referred to as aluminized MYLAR film. The aluminized MYLAR film has a conductive aluminum coating applied to only one of the major surfaces; the other major surface is non-aluminized and therefore non-conductive. The design, construction, and sources for single-sided aluminized MYLAR films are well known to those skilled in the art. The non-aluminized surface of the inner shield 116 is in contact with an outer surface of the belting 112. The inner shield 116 may be characterized as having a thickness of less than or equal to 0.04 mm.
The belting 112 provides the advantage of maintaining transmission line characteristics and providing a consistent radial distance between the first and second conductor 102, 104 and the inner shield 116. The belting 112 further provides an advantage of keeping the twist lay length between the first and second conductors 102, 104 consistent. Shielded twisted pair cables found in the prior art typically only have air as a dielectric between the twisted pair and the shield. Both the distance between first and second conductors 102, 104 and the inner shield 116 and the effective twist lay length of the first and second conductors 102, 104 affect the wire cable impedance. Therefore a wire cable with more consistent radial distance between the first and second conductors 102, 104 and the inner shield 116 provides more consistent impedance. A consistent twist lay length of the first and second conductors 102, 104 also provides controlled impedance.
Alternatively, a wire cable may be envisioned incorporating a single dielectric structure encasing the first and second insulators to maintain a consistent lateral distance between the first and second insulators and a consistent radial distance between the first and second insulators and the inner shield. The dielectric structure may also keep the twist lay length of the first and second conductors consistent.
As shown in
As illustrated in
The wire cable 100 shown in
The wire cable 100 is constructed so that the inner shield 116 is tight to the belting 112, the outer shield 124 is tight to the drain wire 120 and the inner shield 116, and the jacket 126 is tight to the outer shield 124 so that the formation of air gaps between these elements is minimized or compacted. This provides the wire cable 100 with controlled magnetic permeability.
The wire cable 100 may be characterized as having a differential impedance of 95 Ohms.
Therefore, as shown in
As illustrated in the non-limiting example of
As illustrated in
Referring once again to
As illustrated in
The first and second plug terminals 160, 162 are not received within the first and second receptacle terminals 132, 134, therefore the first contact area is on the exterior of the first plug terminal 160 and the second contact area is on the exterior of the second plug terminal 162 when the plug connector 130 is mated to the receptacle connector 128.
The first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 may be formed from a sheet of copper-based material. The first and second cantilever beam portions 136, 140 and the first and second planar portions 164, 166 may be selectively plated using copper/nickel/silver based plating. The terminals may be plated to a 5 skin thickness. The first and second receptacle terminals 132, 134 and the first and second plug terminals 160, 162 are configured so that the receptacle connector 128 and plug connector 130 exhibit a low insertion normal force of about 0.4 Newton (45 grams). The low normal force provides the benefit of reducing abrasion of the plating during connection/disconnection cycles.
As illustrated in
As shown in
The jacket crimp wings 178 are also bypass type wings that are offset and configured to surround the jacket 126 of the wire cable 100 when the lower plug shield 172A is crimped to the wire cable 110.
As illustrated in
Referring again to
The insulation crimp wings are also bypass type wings that are offset and configured to surround the jacket 126 of the wire cable 100 when the lower receptacle shield 174A is crimped to the wire cable 100.
As illustrated in
While the exterior of the plug shield 172 of the illustrated example is configured to slideably engage the interior of the receptacle shield 174, alternative embodiments may be envisioned wherein the exterior of the receptacle shield 174 slideably engages the interior of the plug shield 172.
The receptacle shield 174 and the plug shield 172 may be formed from a sheet of copper-based material. The receptacle shield 174 and the plug shield 172 may be plated using copper/nickel/silver or tin based plating. The first and upper receptacle shield 174A, 174B and the first and upper plug shield 172A, 172B may be formed by stamping processes well known to those skilled in the art.
While the examples of the plug connector 130 and receptacle connector 128 illustrated herein are connected to a wire cable, other embodiments of the plug connector and receptacle connector may be envisioned that are connected to conductive traces on a circuit board.
To meet the requirements of application in an automotive environment, such as vibration and disconnect resistance, the wire cable assembly may further include a receptacle connector body 190 and a plug connector body 192 as illustrated in
Accordingly, a connector assembly is provided. The connector assembly is suited for terminating wire cables 100 and is capable of transmitting digital data signals with data rates of 3.5 Gb/s or higher without modulation or encoding. The connector assembly provides the benefit of improved electromagnetic shielding of the plug terminals 160, 162 and receptacle terminals 132, 134 due to the decreased effective lengths of the plug shield 172 and receptacle shield 174 provided by the location of the shield crimp wings 176 in close proximity to the attachment portions 144 of the terminals. The connector assembly also provides the benefit of improved electrical connections between the upper plug and receptacle shields 172B, 174B and the outer shields 124 of the wire cables 100.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely prototypical embodiments.
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
In the following claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Additionally, directional terms such as upper, lower, etc. do not denote any particular orientation, but rather the terms upper, lower, etc. are used to distinguish one element from another and locational establish a relationship between the various elements.
Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 USC § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
This application is a continuation-in-part application and claims the benefit under 35 U.S.C. § 120 of U.S. patent application Ser. No. 15/369,973, filed Dec. 6, 2016 which claims the benefit under 35 U.S.C. § 120 of U.S. patent application Ser. No. 14/101,472, filed Dec. 12, 2013, the entire disclosure of both of which is hereby incorporated herein by reference.
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20180062280 A1 | Mar 2018 | US |
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Parent | 14101472 | Dec 2013 | US |
Child | 15369973 | US |
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Parent | 15369973 | Dec 2016 | US |
Child | 15804444 | US |