Patent Grant
11211737
This application claims priority to European Patent Application No. 19168567.6, filed on Apr. 11, 2019.
The invention relates to a network connector module for a network connector, to a network connector assembly as well as to a method to assemble the network connector module and to a method to assemble the network connector. Example embodiments of the network connector are suitable for network communication at data rates of at least up to 1 Gbit/s. Further the network connector may be used in automotive applications.
Network connectors capable of network communication at data rates of at least 1 Gbit/s may be used in automotive applications, such as vehicles. In recent years, vehicles have been equipped with numerous on-board electronics. These on-board electronics provide a wide field of functionality, such as sensors, control functions and the like. These on-board electronics provide typical consumer electronic functions, navigation control and/or safety features, as well as e.g. feedback control for autonomous driving. For data communication between single on-board electronic components, data networks have been established within vehicles. These data networks communicate at high data rates, to allow for a safe and reliable communication. Typically, data networks are based on Ethernet networks, operating at data rates up 1 Gbit/s.
To achieve high data rates, specific network communication connectors (data connectors) are used. These specific data connectors come along with a specific plug interface, typically including shielding sheet metal elements. The specific plug interface and shielding sheet metal elements are necessary to reduce cross talk. Typically, those specific plug interfaces cannot easily be combined with known standardized interfaces. Standardized interfaces typically provide ground- and signal contacts in a defined pattern, such as a line and row pattern. Within a line or row, adjacent contacts (ground-and/or signal contacts) may have a defined pitch s of about 1.5 mm, 1.8 mm or 2.0 mm Those standardized interfaces are not suited for network communication at data rates of at least up to 1 Gbit/s but are generally used for signal transmission of digital I/O-signals or for network communication at data rates of at most 100 Mbit/s.
Generally, the higher the data rate, the higher is the cross-talk level between single branches of the network, particularly if electrical contacts, connectors and/or cables of these branches are arranged adjacent and substantially parallel to each other. This is typically the case, if a cable harness is used for wiring the vehicle. Further, the cross-talk level is higher, the closer the single branches of the network are adjacent to each other. As standardized interfaces, have a very low row-pitch and/or line-pitch, these standardized interfaces are prone to high cross talk levels, when being used for the high data rate communication.
Further, with increased data rates, the EMC properties (electro magnetic compatibility) of connectors decreases. Thus, different connectors are provided for 1 Gbit/s networks. To overcome increased cross-talk levels and reduced EMC properties at data rates up to 1 Gbit/s, electrical shielding members are typically provided in a housing of known specific network connector or the network connector system, to prevent radiation from entering and/or leaving the connector housing. Said electrical shielding members typically entirely surround the connector housing, thereby providing good shielding performance. However, such electrical shielding members cause additional manufacturing costs and cannot be simply introduced in known standardized connectors.
An illustrative example embodiment of a network connector module for a network connector is adapted for network communication with data rates of at least up to 1 Gbit/s. The single module as well as a network connector, comprising at least one network connector module is adapted for network communication with data rates of at least up to 1 Gbit/s. The network connector module is adapted to be received within a network connector module receptacle, such as a cavity, of the network connector. The network connector is adapted to be coupled to a corresponding counter connector, for network communication.
The network connector module comprises a shielded cable, wherein the cable includes at least two wires. The wires are adapted for transmitting data for network communication. The network connector module further comprises at least two electrical contact terminals for electrically contacting data contacts of a corresponding counter connector, wherein each of the electrical contact terminals is electrically connected to a respective one of the wires of the cable. Accordingly, the electrical contact terminals of the network connector module are adapted for transmitting data for network communication.
The network connector module further comprises a module housing of electrically insulating material. The electrically insulating material may include plastic material, such as a thermoplastic material or a thermosetting material, a ceramic material, or the like. Particularly, the module housing may be formed by injection molding.
The module housing comprises at least two terminal receptacles that are arranged directly adjacent to each other, each of the terminal receptacles receives one of the electrical contact terminals. Providing the terminal receptacles, respectively the electrical contact terminals adjacent to each other, allows to communicate using differential signal pairs, wherein the adjacent electrical contact terminals may form a differential signal pair.
The network connector module further comprises an electrical shielding member made of cut and bent sheet metal. The electrical shielding member allows to provide network communication with network connector module at data rates of at least up to 1 Gbit/s. The network connector module may have an impedance Zd in the range of 95 to 105Ω. Further, the network connector module may have a return loss RL of less than −30 dB (preferably less than −50 dB) at frequencies of less than 200 MHz and a return loss RL of less than −20 dB (preferably less than −30 dB) at frequencies in the range of 200 MHz to 600 MHz. Further, the network connector module may have a insertion loss IL of less than −0.1 dB at frequencies of less than 600 MHz.
The electrical shielding member is in electrical contact with a shielding of the cable, and the electrical shielding member at least partially surrounds the module housing. The electrical shielding member includes at least two contact elements for electrically contacting ground contacts of a corresponding counter connector. The contact elements are arranged lateral of the module housing, so as to be in a row with the electrical contact terminals received in the module housing. Further, the contact elements sandwich the electrical contact terminals. Accordingly, the contact elements and contact terminals are adapted to contact respective ground contacts (G) and data contacts (S) of a corresponding counter connector, wherein the ground contacts (G) and data contacts (S) are arranged in at least one row, having the following repeating contact pattern: GSSG. Multiple GSSG contact patterns may be arranged in a row of the interface, resulting in a repeating . . . GSSGGSSG . . . contact arrangement within one row. Alternatively, adjacent GSSG contact patterns can share a common ground contact, resulting in a repeating . . . GSSGSSG . . . contact arrangement within one row.
Arranging the contact elements and the electrical contact terminals in a row, as described above, allows to contact a corresponding counter connector, that has a standardized interface. The pitch between two adjacent contacts (ground- and/or signal contacts) may be about 1.5 mm, 1.8 mm or 2.0 mm Other pitches may be used instead. Thus, the network connector module can be used or inserted into known connectors, thereby providing high data rates with known connectors.
The electrical shielding member may comprise a receiving portion for receiving the module housing, wherein the contact elements protrude inwardly in receiving portion, so that, when the network connector module (respectively the network connector) is coupled to a corresponding counter connector, the contacting ground contacts and the data contacts of a corresponding counter connector are at least partly received in the receiving portion of the module housing. Inwardly protruding contact elements allow to provide a reliable electrical shielding member, as the shielding member protects the contact elements from getting damaged. Further, as the receiving portion of the electrical shielding member at least partially receives the ground contacts and data contacts of a corresponding counter connector, the shielding properties can be improved. Thus, less crosstalk occurs. A network connector module comprising inwardly protruding contact elements is adapted to contact respective ground contacts (G) and data contacts (S) of a corresponding counter connector having a . . . GSSGGSSG . . . contact pattern.
Further, the contact elements may protrude outwardly from the receiving portion, so that, when the network connector module is coupled to a corresponding counter connector, the contacting ground contacts are not received within the receiving portion of the module housing and the data contacts of a corresponding counter connector are at least partly received in the receiving portion of the module housing. A network connector module comprising outwardly protruding contact elements is adapted to contact respective ground contacts (G) and data contacts (S) of a corresponding counter connector having a . . . GSSGGSSG . . . contact arrangement or having a . . . GSSGSSG . . . contact arrangement.
The electrical shielding member may have a substantially rectangular cross section, having an inner height, measured from a bottom wall to a top wall of the electrical shielding member in the range of 2.5 mm to 3.3 mm, preferably in the range of 2.9 mm to 3.2 mm, and most preferably of about 3.1 mm With providing a height as described above, an air gap can be included in the receiving portion. This air gap allows to provide an impedance Zd in the range of 95 to 105 Ohms. Further, with said inner height a small module can be provided that can be used in known connectors. Preferably, the width of the shielding member, i.e. the width from a sidewall to a sidewall (measured outwardly), is in the range of 5.8 to 6.3 mm, preferably in the range of 5.9 to 6.2 mm and most preferably about 6.1 mm Thus, size can be further reduced, while impedance requirements are met, and high network communication data rates can be achieved.
The electrical shielding member may comprise a receiving portion for receiving the module housing, wherein the receiving portion is substantially U-shaped, and wherein the contact elements protrude outwardly from the receiving portion, so that when the network connector module (respectively the network connector) is coupled to a corresponding counter connector, the contacting ground contacts are not received in the receiving portion of the module housing. Outwardly protruding contact elements allow to further reduce the size of the shielding member, and accordingly of the network connector module. In particular, the width of the network connector module can be further reduced, while still providing data communication rates of at least up to 1 Gbit/s. The receiving portion has a U-shape seen in the direction against the mating direction A of the network connector module. Accordingly, the receiving portion at least partially surrounds the module housing on a bottom side and (at least partially) on two sidewalls thereof. This allows for reduced crosstalk and improved shielding properties.
The contact elements may be embossed elements, that can be integrally formed with a respective side wall of the receiving portion. Providing embossed contact elements allows to reduce manufacturing costs. In particular, the embossed elements can be provided as contact arms having a free end. Further, the embossed elements can be provided as contact protrusions that are connected to the sidewall on at least two ends of the respective embossed element. Free arms are more flexible and therefore allow to contact a ground or data contact, having a greater tolerance, wherein contact protrusions are more reliable and allow for higher contact forces.
The contact elements can be contact arms, that have a free end, wherein the free end may face in the mating direction A. Providing a contact arm with a free end that faces in the mating direction A leads to a shielding member design that is easy to manufacture and has reduces material consumption. The contact elements and in particular the contact arms may be provided at a front portion of the network connector module (i.e. adjacent to an end of the network connector module facing in mating direction A). In particular, the contact elements of the electrical shielding member may be arranged respective to the contact terminals of the network connector module so that upon coupling the network connector module (or the respective network connector) with a corresponding counter connector, the contact elements electrically contact the ground contact of the corresponding counter connector before the contact terminals electrically contact the data contact of the corresponding counter connector. Therefore, shielding is achieved before network communication can start. Thus, distortion (e.g. due to crosstalk) of adjacent network branches can be prevented or at least reduced.
The electrical shielding member may comprise at least one locking element that is adapted to engage with a corresponding locking element of the module housing for locking the module housing with the electrical shielding member. By locking the locking element of the electrical shielding member with the corresponding locking element of the module housing allows to lock the module housing and the electrical shielding member securely with each other. Thus, it can be prevented that the module housing and the electrical shielding member are separated from each other during use. Further, the locking element and the corresponding locking element allow for an easy manufacturing of the module and therefore to reduced manufacturing costs.
The at least one locking element may be a latching arm that can be provided on rearward portion of the electrical shielding member. Particularly, the at least one locking element may be provided at a bottom wall of the electrical shielding member. Providing the locking element on the rearward portion of the electrical shielding member allows to insert the module housing in the receiving portion of the electrical shielding member without being disturbed by the locking element. This is, as the module housing and the locking element come into engagement only, if the module housing is (almost) completely inserted into the receiving portion. Thus, the assembly of the network connector module is facilitated. Further, the locking element may provide a haptic feedback for the user, who assembles the network connector module. Thus, the correct locking can be sensed, and an incorrect assembly of the connector module can be prevented.
At least one locking element may be a through opening provided in a side wall of the receiving portion of the electrical shielding member. Through openings are easy to manufacture and therefore allow for further cost reduction of the shielding member. In particular, the locking elements provided as through openings can be locked with corresponding locking protrusions provided at the module housing.
The shielding member may be provided with different locking elements for providing a reliable locking with the module housing. In case of through openings, there may be at least two through opening on each sidewall of the receiving portion. Further, there may be at least two latching arms on a rearward portion of the electrical shielding member. Further, through openings and latching arms can be present at a shielding member for providing a secure locking. Other locking elements may also be used.
The electrical shielding member and/or the module housing includes a latching element for latching with a network connector. This allows for a reliable and preferably tool-less assembly of the module within the network connector. The latching elements may be provided in form of a latching arm or a latching recess that latches with a corresponding latching element of the network connector. Further, multiple latching elements may be provided wherein the latching elements may have different forms.
The electrical shielding member may comprise at least one guiding shoulder, for linearly guiding the module housing during the insertion of the module housing in the receiving portion. The guiding shoulder may be formed by a stepped portion in the top wall of the receiving portion of the electrical shielding member. Further, the top wall of the receiving portion may at least be partially cutout so as to receive the module housing. The guiding shoulders facilitate the manufacturing and assembly of the network connector module and at the same time may serve to guide the network connector module when the network connector module is inserted in a network connector module receptacle network connector. Thus, no additional guiding surfaces need to be provided and a small network connector module can be achieved.
The contact elements and the electrical contact terminals may be arranged so as to be adapted to electrically contact ground contacts and data contacts of a corresponding counter connector that have an equidistant pitch in row direction, wherein the pitch may be about 1.5 mm, 1.8 mm or 2.0 mm Other pitches may be used instead. Thus, the network connector module may be used with standardized interfaces.
The object is further at least partly achieved by a network connector assembly that is capable of communicating at data rates of at least up to 1 Gbit/s, wherein the network connector assembly comprises a network connector housing, and at least two network connector modules, as described above. In particular, the network connector housing may be a housing of a network connector that has a standardized interface, having a row pitch of 1.5 mm, 1.8 mm or 2.0 mm Other pitches may be used instead.
The network connector housing comprises network connector module receptacles, for receiving the at least two network connector modules. Those module receptacles may be spaced apart from each other (in row direction) of about 4 times the pitch, i.e. of about 6 mm (4×1.5 mm), or of about 7.2 mm (4×1.8 mm) or of about 8 mm (4×2 mm), in case a . . . GSSGGSSG . . . contact arrangement is used, depending on the row pitch used. The contact elements and contact terminals may be adapted to contact respective ground contacts (G) and data contacts (S) of a corresponding counter connector, wherein the ground contacts (G) and data contacts (S) are arranged in at least one row, having the following repeating contact arrangement . . . GSSGGSSG . . . .
In case adjacent GSSG contact patterns share a common ground contact, i.e. in case a . . . GSSGSSG . . . contact arrangement us used, module receptacles may be spaced apart from each other (in row direction) of about 3 times the pitch, i.e. of about of about 4.5 mm (3×1.5 mm), or of about 5.4 mm (4×1.8 mm) or of about 6 mm (4×2 mm).
The network connector housing may comprise single row or multiple rows of network connector module receptacles, wherein each row may comprise at least two, preferably at least 4 and most preferably at least 8 of network connector module receptacles. Accordingly, the network connector assembly may comprise a single row or multiple rows of network connector modules, wherein each row may comprise at least two, preferably at least 4 and most preferably at least 8 of network connector modules.
The network connector assembly may further comprise at least two network connector module seals that are received in the network connector module receptacles and a seal retaining member that is adapted to be coupled to the network connector housing and to retain the network connector modules and the network connector module seals within the network connector module receptacles. Thus, a sealed network connector can be provided.
An illustrative example embodiment of a method for assembling a network connector module as described above includes inserting the module housing in the receiving portion of the electrical shielding member, and locking the module housing with the electrical shielding member. This allows for a reliable assembly, while saving costs.
An illustrative example embodiment of a method for assembling a network connector assembly as described above includes providing at least two network connector modules, providing the network connector housing, inserting each network connector module in a respective network connector module receptacle of the network connector housing, and latching the network connector module with the network connector housing. This allows for a reliable assembly, while saving costs.
In the following, preferred embodiments of the invention are described in relation to the accompanied figures, wherein
The electrical shielding member 100 comprises a receiving portion 110 for receiving a module housing 300. Further, the electrical shielding member 100 may comprise a latching element 120 for latching the network connector module 10 with a network connector (not shown). Further, the electrical shielding member may at least partially surround the module housing 300 on a bottom side 116 and at least partially on two sides, i.e. at sidewalls 118, 119.
The electrical shielding member includes at least two contact elements 130, 140 for electrically contacting ground contacts of a corresponding counter connector (not shown). The contact elements 130, 140 may be provided in respective sidewalls 118, 119 of the receiving portion 110 of the electrical shielding member 100.
The network connector module 10 may comprises data pin receptacles 14a, 14b and ground pin receptacles 16a, 16b. Those receptacles are arranged in a row wherein the contact elements of the electrical shielding member are adapted for electrically contacting ground contacts (ground pins) of a corresponding counter connector and the contact terminals (not shown) are arranged for contacting data contacts (signal pins). As the contact elements sandwich the electrical contact terminals, the contact elements 130, 140 and the contact terminals are adapted to contact respective ground contacts and data contacts of a corresponding counter connector (not shown), wherein the ground contacts and the data contacts are arranged in at least one row having a repeating contact pattern of ground contact-data contact-data contact-ground contact (GSSG). Multiple GSSG contact patterns may be arranged in a row of the interface, resulting in a repeating . . . GSSGGSSG . . . contact arrangement within one row (cf.
The ground pin receptacle and signal pin receptacle may have a pitch s, wherein the pitch s may be about 1.5 mm, or about 1.8 mm, or about 2.0 mm Other pitches may be used instead. Further, the module housing may have corresponding locking elements 331, 341 that are adapted to be locked with primary locking means 531, 541 of electrical contact terminals 530, 540, as shown in
The shield 410 of the cable 400 can be folded back and can be secured by means of an inner ferrule 200. The inner ferrule 200 forms a sleeve that is formed from cut and bent sheet metal and may surround the cable 400 at least partially. Then, the cable reception 160 can be crimped over the ferrule 200, thereby securing the cable 400 and the ferrule 200 within the electrical shielding member 100.
On a rearward portion of the electrical shielding member 100, preferably on a bottom wall 116, locking elements 152, 154 may be provided which lock with a corresponding locking element 352 of the module housing 300. Thus, the module housing 300 can be secured (locked) in the electrical shielding member 100. The cable reception 160 may also be assembled (joint) by respective contoured edges 162, 164 that may comprise a puzzle shape form. The contoured locking edges of the divided bottom wall and the cable reception allow for a stable and reliable connection of the edges. Further, the electrical shielding member 100 may be formed from a single piece of sheet metal. Thereby providing a low-priced shielding member.
The primary locking element 531, 541, the corresponding primary locking element 331, 341, the secondary locking elements 533, 543, the corresponding secondary locking elements may be arranged so that, when pulling the cable 400 out of the connector module 10, 10′, firstly the primary locking elements 531, 541 and the corresponding primary locking elements 331, 341 abut each other. Subsequently, the secondary locking elements 533, 543 and the corresponding secondary locking elements may abut each other. Thus, the cable 400 can be held reliable with in the network connector module, without losing its electrical connection.
The primary locking elements 531, 541 of the electrical contact terminals 530, 540 may be provided as latching arms and the secondary locking elements 533, 543 may be provided as locking recess that receive a corresponding secondary locking element.
The terminals 530, 540 may be provided with crimping means 535, 545 for electrically contacting the wires 430, 440 of the cable 400. Further, each terminal 530, 540 comprises a contact pin receptacle for receiving and electrically contacting a respective data contact or signal pin.
Further, the electrical shielding member 100′ may comprise a cable reception 160′ for receiving the cable 400. The cable reception 160′ may be provided with a retaining protrusion 160′ that protrudes inwardly into the cable reception 160′ and thereby improves the connection between the cable and the shielding member 100′. The electrical shielding member 100′ has a substantially U-shaped cross section when seen from a direction opposite to the mating direction A. Further, the electrical shielding member 100′ comprises contact elements 130′, 140′ that protrude outwardly from the receiving portion 110′. These contact elements may be provided as contact arms, each having a free end facing in mating direction A.
As the contact elements 130′, 140′ protrude outwardly from the receiving portion 110′, the network connector module 10′ can be coupled to a corresponding counter connector, so that the contacting ground contacts are not received within the receiving portion 110′ of the module housing wherein the data contacts of a corresponding counter connector are at least partly received in the receiving portion 110′ of the module housing. The network connector module 110′ comprising outwardly protruding contact elements 130′, 140′ is adapted to contact respective ground contacts (G) and data contacts (S) of a corresponding counter connector having a . . . GSSGGSSG . . . contact arrangement (cf.
The shielding member 100′ may comprise locking elements 150′, 153′, 154′, 155′, provided as locking through holes in sidewalls 118′, 119′ of the receiving portion. The housing 300′ comprises corresponding locking elements 352′, 353′ that can engage (lock) with the locking elements of the shielding member 100′. Shielding member 100′ surrounds the module housing 300′ at least partially, wherein it covers the bottom and the sides of the module housing 300′ at least partially.
Further, housing 300′ may comprise a tertiary locking element 320a′. The tertiary locking element 320a′ may be arranged on the housing 300′ at a front portion of the network connector module 10′ (i.e. adjacent to an end of the network connector module facing in mating direction A). Further, the tertiary locking element 320a′ may protrude outwardly from housing 300′. The tertiary locking element 320a′ may serve to lock with a secondary locking device (CPA) of the network connector and/or with a TPA (Terminal Position Assurance) member of the network connector. This allows for redundant locking of both the contact terminals 530, 540 and the network connector module with the network connector.
The mating direction A of the angled contact pins lies within the image plane of
The network connector modules 10a″, 10b″ are coupled to ground contacts 6a′, 6bc′, 6d′ and data contacts 4a′, 4b′, 4c′, 4d′ of a corresponding counter connector (not shown). The ground and data contacts 6a′, 6bc′, 6d′, 4a′, 4b′, 4c′, 4d′ are provided as contact pins having an angled form. Further, the ground and data contacts 6a, 6b, 6c, 6d, 4a, 4b, 4c, 4d are provided in a repeating GSSG-pattern forming a . . . GSSGSSG contact arrangement. Particularly, adjacent GSSG contact patterns of
The mating direction A of the angled contact pins lies within the image plane of
Further, as shown in the front view, the network connector 1 comprises a signal terminal 60 having multiple signal pins for transmitting digital I/O signals. In a top row, there are six network connector modules 10a to 10f provided.
The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this invention. The scope of legal protection given to this invention can only be determined by studying the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 19168567 | Apr 2019 | EP | regional |
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| Entry |
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| Extended European Search Report for Application No. EP 19 16 8567 dated Jan. 10, 2019. |
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| Number | Date | Country | |
|---|---|---|---|
| 20200328553 A1 | Oct 2020 | US |
