Cap assembly with at least one impedance control structure
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TE CONNECTIVITY GERMANY GMBH
- Filing Date
- 2020-08-25
- Publication Date
- 2026-06-05
Smart Images
Figure CN112448237B_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a cover assembly, and more particularly, to a cover assembly for protecting the connection between electrical conductors of a high-frequency data transmission line, especially at operating frequencies in the gigahertz range. Background Technology
[0002] In the field of data transmission, transmission lines typically consist of multiple components, such as connectors, cables, wires, and sockets. These transmission line components are interconnected to establish the necessary signal channels. This interconnection can be achieved through connection devices, such as plug and socket mechanisms, or through permanent bonding. The connection devices need to provide reliable electrical contact between the transmission line components. In the case of permanent bonding, reinforcement devices are also provided around the permanent bonding to increase its mechanical stability.
[0003] In applications requiring high-frequency data transmission, the connection and enhancement devices themselves may negatively impact the performance of the signal channel, thereby reducing signal quality and transmission performance, respectively.
[0004] Technical problems to be solved
[0005] The object of this invention is to provide an apparatus for reliably transmitting high-frequency signals, particularly in the gigahertz range. Summary of the Invention
[0006] The aforementioned problem is solved by providing at least one impedance control structure in a cover assembly comprising a protective cover and at least two electrical conductors for conducting electrical signals for high-frequency data transmission, wherein the at least two electrical conductors extend through the protective cover in the transmission direction and are overlapped and coupled to each other at at least one coupling location located within the protective cover. The at least one coupling location and the protective cover affect the impedance of the at least two electrical conductors. Therefore, the problem is solved in particular by providing at least one impedance control structure on the protective cover to adjust the impedance of the at least two electrical conductors to a predetermined value according to the frequency of data transmission. Thus, the effects of the at least one coupling location and the protective cover are compensated.
[0007] Impedance is generally a measure of an electrical conductor's resistance to alternating current. Impedance is affected by a variety of factors, such as the material and size of the conductor itself, the average relative permittivity of the medium surrounding the conductor (dielectric material), and other conductive or capacitive components near the conductor, particularly the relative distance between the corresponding surfaces.
[0008] Signal reflection may occur if the impedance of the load and the impedance of the transmission line are mismatched (impedance mismatch) when transmitting an electrical signal from the signal source to the signal receiver (load) via a transmission line. Signal reflection impairs signal integrity and is therefore undesirable. This impedance mismatch and subsequent signal reflection may be caused by nonlinear variations in the cross-section of the conductor in the transmission line, discontinuities in the material around the conductor, or sharp bends in the path of the transmission line.
[0009] Therefore, it is preferable to match the impedance of the transmission line to the impedance of the load and eliminate the causes of impedance mismatch. In other words, it is preferable to adjust the impedance of the transmission line to a predetermined value. Such a predetermined value can be the impedance of the load.
[0010] The above solution is advantageous because it compensates for at least one cause of impedance mismatch, thereby reducing signal reflection. Therefore, it significantly improves the signal integrity of the transmitted signal and increases the reliability of signal transmission.
[0011] The solution described above can be further improved by adding one or more of the following optional features. Therefore, each of these optional features is advantageous on its own and can be combined independently with any other optional feature.
[0012] According to the first embodiment, one of the at least two electrical conductors can be a wire of a cable, preferably a wire of a shielded cable including at least one stripped end. The corresponding other of the at least two electrical conductors can be a contact element of a connector, preferably a pin-shaped contact element of a shielded connector. In this embodiment, the wire and the contact element can together form a signal path for high-frequency data transmission.
[0013] As will be described in further detail below, due to at least one impedance control structure, the signal path has an impedance equal to a predetermined value. Therefore, the cover assembly can be used as protection for the connection between the shielded cable and the shielded connector.
[0014] More specifically, the conductor may include at least one terminal portion, wherein the at least one terminal portion may protrude into the protective cover away from at least one stripped end of the shielded cable. The contact element may include a coupling portion having at least one coupling protrusion, wherein the at least one coupling protrusion may protrude into the protective cover away from at least one coupling portion. The at least one terminal portion may also at least partially overlap with the at least one coupling protrusion at at least one coupling location within the protective cover. Additionally, the at least one terminal portion may at least partially engage with the at least one coupling protrusion at at least one coupling location within the protective cover.
[0015] This embodiment allows the cover assembly to be used in conjunction with a cable, enabling data transmission over longer distances and thus increasing the functionality of the invention. Furthermore, this embodiment allows the cover assembly to be used in conjunction with a connector, further expanding the applicability of the invention.
[0016] Optionally, the cover assembly may include a first conductor of the cable, a second conductor of the same cable, a first contact element of the connector, and a second contact element of the same connector, wherein the first conductor and the first contact element together form a first signal path, and the second conductor and the second contact element together form a second signal path, and the first signal path and the second signal path form a pair of signal paths. Preferably, the pair of signal paths may be configured to be spaced apart from each other and electrically isolated. Furthermore, each of the pair of signal paths may be configured to transmit one signal from a differential signal pair for high-frequency data transmission.
[0017] As will be described in further detail below, due to at least one impedance control structure, the signal path has an impedance equal to a predetermined value. Therefore, the cover assembly can be used as protection for the connection between a shielded two-strand cable and a shielded two-strand connector.
[0018] More specifically, the first and second conductors may each include at least one terminal portion, wherein the terminal portions may protrude into the protective cover in a spaced-apart arrangement away from the cable. The first and second contact elements may each include at least one engagement portion. Each engagement portion may include at least one engagement protrusion that may protrude into the protective cover away from the corresponding engagement portion. At least one terminal portion of the first conductor may at least partially overlap with at least one engagement protrusion of the first contact element at a first engagement position within the protective cover, while at least one terminal portion of the second conductor may at least partially overlap with at least one engagement protrusion of the second contact element at a second engagement position within the protective cover. At least one terminal portion of the first conductor may at least partially engage with at least one engagement protrusion of the first contact element at the first engagement position within the protective cover, while at least one terminal portion of the second conductor may at least partially engage with at least one engagement protrusion of the second contact element at the second engagement position within the protective cover.
[0019] This embodiment allows data transmission to be less susceptible to electromagnetic noise due to the transmission of differential signal pairs.
[0020] Furthermore, the centerlines of the signal paths can be parallel to each other along the entire length of the cover assembly. More specifically, the conductor pitch of the first and second conductors can be equal to the contact pitch of the first and second contact elements. This embodiment particularly prevents conductor scattering, which can lead to sharp bends. Therefore, at least one possible cause of signal reflection is eliminated, further improving signal integrity.
[0021] According to another embodiment, the protective cover may be overmolded at at least one mating location and is made of an insulating material, preferably an insulating material with a relative permittivity higher than that of air. Furthermore, the overmolding may extend beyond a portion of each of at least two electrical conductors. More specifically, at least two electrical conductors may be at least partially embedded within the overmolding.
[0022] This embodiment allows for the manufacture of protective caps using an automated low-pressure overmolding process. Therefore, this embodiment helps simplify the manufacturing process.
[0023] According to an alternative embodiment, the protective cover may include at least two parts connected to each other to form the protective cover. More particularly, the protective cover may be formed together by a pair of prefabricated cover halves that engage in a form-fitting manner. Preferably, the pair of prefabricated cover halves may include a latching mechanism, wherein at least one latching cam and at least one latching groove are arranged on each cover half, and at least one latching cam on each cover half is configured to engage with at least one latching groove on the corresponding other cover half to form a latching connection.
[0024] This embodiment allows for the assembly of the protective cap through an automated pick-and-place assembly process. Therefore, this embodiment provides an alternative that also helps simplify the manufacturing process.
[0025] Optionally, the lid halves can be identical to each other. Preferably, the lid halves have a hermaphroditic design, which further simplifies the manufacturing process because it is not necessary to distinguish between different types of lid halves.
[0026] Alternatively or additionally, the protective cover may include an inner wall that at least partially spacees one of the signal paths from the other. This embodiment prevents direct contact between the signal paths, thereby reducing the risk of electrical short circuits.
[0027] In another embodiment, at least one impedance control structure may include at least one recess on the outer surface of the protective cover. The at least one recess is an impedance control structure that allows easy adjustment of at least one impedance influencing factor, namely the average relative permittivity of the dielectric material.
[0028] More specifically, recesses can be locally formed on the outer surface of the protective cover in areas where it is necessary to increase the impedance of at least two electrical conductors to achieve a predetermined value, and to compensate for the effects of having one less bonding location and protective cover. This can be, for example, in areas where at least two electrical conductors are surrounded by an insulating material with a relative permittivity higher than that of air, and where the cross-sections of the at least two electrical conductors are increased, for example, due to overlap. In such areas, the recess will result in an air-filled space. Since the relative permittivity of air is lower than that of the insulating material, the resulting dielectric material (partially air, partially insulating material) will have a lower average relative permittivity, leading to an increase in the impedance of the at least two electrical conductors.
[0029] Additionally or alternatively, at least one impedance control structure may be included in the protective cover, or at least one lead through-hole may be connected to at least two outer surfaces of the protective cover. Preferably, at least one lead through-hole may extend through the insulating material as a cylindrical, cuboid, or motion field-shaped cavity in a direction perpendicular to the transmission direction.
[0030] At least one via is also an impedance control structure, allowing easy adjustment of at least one impedance influencing factor, namely the average relative permittivity of the dielectric material. In embodiments including a pair of signal paths, at least one via can preferably extend between the pair of signal paths. This creates an air-filled space between the pair of signal paths, which leads to a decrease in the average relative permittivity of the dielectric material and an increase in the impedance of the pair of signal paths, since the relative permittivity of air is generally lower than that of the insulating material. Therefore, at least one via can be used in applications where the impedance of the pair of signal paths needs to be increased to reach a predetermined value and compensate for the effects of at least one bonding location and protective cap.
[0031] Optionally, at least one impedance control structure may include at least one lateral recess on the side surface of the protective cover. Preferably, at least one pair of lateral recesses may extend symmetrically on two opposite side surfaces of the protective cover. Furthermore, each of the pair of lateral recesses may extend at least along the entire length of the mating position in the transmission direction. Additionally, in a direction parallel to the lead via, at least one pair of lateral recesses may extend along the entire length of the lead via.
[0032] More specifically, each of the pair of lateral recesses can be a trapezoidal, cuboid, or circular cutout in the insulating material of the protective cover, extending perpendicular to the transmission direction and parallel to the lead through-hole. The cutout can preferably extend along the entire height of the respective side surface, a height that is a dimension in the direction perpendicular to the transmission direction and parallel to the lead through-hole.
[0033] Optionally, each of the pair of transverse recesses includes at least one chamfered edge at its end in the transport direction. The at least one chamfered edge improves the manufacturability of the transverse recess during the casting process because it acts as a draft force, thereby simplifying the demolding step.
[0034] In another embodiment, at least one impedance control structure may include or include at least one capacitor element, preferably a conductive capacitor element disposed on at least one outer surface of the protective cover. More specifically, at least one capacitor element may be a metal plate disposed in a retaining groove on at least one outer surface of the protective cover, or glued thereto.
[0035] In embodiments comprising a pair of prefabricated cover halves, at least one capacitive element may alternatively be at least one metal clip, a bent sheet metal piece, or a braided metal piece that holds the pair of prefabricated cover halves together. More specifically, the pair of prefabricated cover halves may be at least partially surrounded by or in direct contact with the metal clip, the bent sheet metal piece, or the braided metal piece.
[0036] At least one capacitive element is an impedance control structure that allows adjustment of at least one impedance influence factor, i.e., the relative distance between the surfaces of at least two electrical conductors and the surface of at least one capacitive element. Specifically, this relative distance is shortened by placing at least one capacitive element on the surface of the protective cover and thus close to the at least two electrical conductors. As a result, the impedance of the at least two electrical conductors is reduced. Subsequently, the at least one capacitive element can be used in applications where it is necessary to reduce the impedance of at least two electrical conductors to a predetermined value and to compensate for the effects of at least one bonding location and the protective cover. This can be, for example, in areas where at least two electrical conductors are surrounded by air, for example, due to manufacturing inaccuracies caused by air filling in the protective cover.
[0037] As an addition or alternative to the same situation, at least one impedance control structure may include a high dielectric constant insulating material used for the protective cover, preferably a material with a relative dielectric constant in the range of 9 to 10. More specifically, an insulating material doped with ceramic powder may be used as the high dielectric constant insulating material for the protective cover. Using a high dielectric constant insulating material can result in a higher average relative dielectric constant of the dielectric material (partially air, partially high dielectric constant insulating material), which will lead to a reduction in the impedance of at least two electrical conductors.
[0038] Optionally, any of the above embodiments of the at least one impedance control structure may be aligned with at least one bonding location. More specifically, the at least one impedance control structure may be confined near and / or locally by the influence region of the at least one bonding location, thereby focusing and maximizing the effect of the at least one impedance control structure.
[0039] According to another embodiment of the invention, the cover assembly may further include a contact carrier for supporting at least one of at least two electrical conductors, wherein one end of the corresponding electrical conductor protrudes freely from the contact carrier into the material of the protective cover. More specifically, the end includes a straight protrusion that is fixedly embedded in the protective cover.
[0040] The contact carrier can be at least one separate component that forms a form-fit with the protective cover. For this purpose, the contact carrier may include a receptacle or groove to receive a protrusion or ball on the protective cover. Alternatively, the contact carrier may be formed as an integral part of the protective cover.
[0041] The advantage of this embodiment is that it provides additional structural support for at least one of the at least two electrical conductors through the contact carrier.
[0042] According to another embodiment, the cover assembly may be part of a connector for high-frequency data transmission and further includes a terminal shield, wherein the protective cover and contact carrier of the cover assembly are located within the terminal shield. The terminal shield may include at least one insertion opening for receiving a mating connector, wherein the mating connector is preferably configured to make electrical contact with at least one of at least two electrical conductors when inserted into the opening of the terminal shield.
[0043] This embodiment enables the cover assembly to be used in conjunction with a mating connector, thereby further expanding the applicability of the invention.
[0044] The technical problem is also solved by providing a method for overmolding a bond between at least one conductor of a cable and at least one contact element having a protective cap made of an insulating material (preferably polyamide). The method includes the following steps: providing at least one contact element; providing at least one conductor; positioning the at least one contact element and at least one conductor in a partially overlapping position; bonding the at least one contact element and at least one conductor, for example by welding, preferably by compaction welding and / or resistance welding, or alternatively by a similar suitable method, such as soldering, brazing, etc.; surrounding the bond with a casting comprising at least one core which forms at least one impedance control structure in the insulating material; injecting the insulating material into the casting; and removing the casting and at least two cores after the injected insulating material has hardened.
[0045] This method allows the protective cover to be manufactured as an overmolded component, thus demonstrating a reliable means of transmitting high-frequency signals (especially in the gigahertz range). Simultaneously, the method allows for the formation of at least one impedance control structure within the insulating material of the protective cover. Therefore, it reduces the manufacturing time of the overmolded protective cover.
[0046] The method described above can be further improved by adding one or more of the following optional steps. Therefore, each of these optional steps is advantageous on its own and can be combined independently with any other optional step.
[0047] In a first embodiment, the method may include the steps of providing at least one contact element, preferably in a 360° accessible orientation; and providing at least one wire, preferably in a 360° accessible orientation.
[0048] Resistance welding can be achieved by providing at least one contact element and at least one lead in a 360° accessible orientation, wherein at least one contact element and at least one lead can be overlapped between two ceramic spacers and then sandwiched between two electrodes, which generate current and apply mechanical force on the overlapped at least one contact element and at least one lead. This resistance welding process has a shorter cooling time, thus improving productivity. It can also be implemented in small-scale applications, enabling miniaturized designs.
[0049] In another embodiment, the method includes the following steps: providing a first contact element; providing a second contact element; providing a first wire; providing a second wire; positioning the first contact element and the first wire at a partially overlapping position to form a first signal path; and positioning the second contact element and the second wire at a partially overlapping position to form a second signal path.
[0050] This embodiment allows for the generation of a pair of signal paths, each of which can be configured to transmit one signal from a differential signal pair for high-frequency data transmission. Therefore, data transmission can be achieved that is less susceptible to electromagnetic noise due to the transmission of the differential signal pair.
[0051] In another embodiment, the method may include the following steps: fixing a first signal path and a second signal path with at least two cores from at least two opposite directions, preferably two opposite directions perpendicular to the transmission direction.
[0052] By fixing the first and second signal paths with at least two cores from at least two opposite directions, undesirable movement of the first and second signal paths is prevented during the injection of insulating material, thereby improving the reliability of the overmolding process.
[0053] According to another embodiment, the method may include the step of inserting a blade between a first signal path and a second signal path, wherein the blade is preferably an integral part of one of at least two cores.
[0054] The blade can be used as an additional or alternative spacer between the first and second signal paths, thereby further preventing undesirable movement of the first and second signal paths during the injection of insulating material. Therefore, the blade can further improve the reliability of the overmolding process.
[0055] Furthermore, the combination of at least two core wires and blades allows for the fabrication of a molded protective cover itself, while forming at least one lead through-hole in the insulating material of the protective cover as an impedance control structure. Attached Figure Description
[0056] In the following description, embodiments of the invention are illustrated with reference to the accompanying drawings. The embodiments shown and described are for illustrative purposes only. The combinations of features shown in the embodiments may be varied based on the foregoing description. For example, if the technical effect associated with a feature is beneficial to a particular application, a feature not shown in the embodiments but described above may be added. Conversely, if the technical effect associated with a feature is not required in a particular application, the feature shown as a part of the embodiments as described above may be omitted.
[0057] In the accompanying drawings, elements that correspond to each other in function and / or structure have been provided with the same reference numerals.
[0058] In the attached diagram:
[0059] Figure 1 A schematic diagram showing a perspective, partially transparent view of a cover assembly and a shielded cable according to a possible embodiment of the present disclosure is provided.
[0060] Figure 2 It shows Figure 1 A magnified view of a portion of the image;
[0061] Figure 3 A schematic diagram showing a perspective, partially transparent view of the cover assembly and shielded cable according to another possible embodiment of the present disclosure is provided.
[0062] Figure 4 It shows that according to Figure 3 A schematic perspective view of the cover assembly and shielded cable of the embodiment shown;
[0063] Figure 5 An exploded schematic diagram of the cover assembly and shielded cable according to another possible embodiment of the present disclosure is shown;
[0064] Figure 6 It shows that according to Figure 5 A schematic perspective view of the cover assembly and shielded cable of the embodiment shown;
[0065] Figure 7A schematic perspective view of the cover assembly and shielded cable according to another possible embodiment of the present disclosure is shown;
[0066] Figure 8 A schematic cross-sectional view of a connector according to one possible embodiment of the present disclosure is shown;
[0067] Figure 9 It shows that according to Figure 8 A schematic perspective view of the connector and mating connector of the embodiment shown;
[0068] Figure 10 A schematic perspective view of a contact carrier according to one possible embodiment of the present disclosure is shown;
[0069] Figure 11 A schematic perspective view of a shielded cable according to a possible embodiment of the present disclosure is shown; and
[0070] Figure 12 A schematic perspective view of a contact carrier, shielded cable, and casting according to one possible embodiment of the present disclosure is shown. Detailed Implementation
[0071] First, refer to Figures 1 to 7 The exemplary embodiments shown illustrate the structure of the cover assembly 1 according to the present invention. Figure 8 and Figure 9 This is used to explain the structure of connector 2 according to the present invention. Figures 10 to 12 Used to explain the method according to the present invention.
[0072] Figure 1 A perspective view of a cover assembly according to one possible embodiment of the present disclosure is shown. The cover assembly 1 includes a protective cover 4 shown in a transparent depiction. The cover assembly 1 also includes a first conductor 6a of a shielded cable 10, a second conductor 6b of the same shielded cable 10, a first contact element 12a of a connector 2, a second contact element 12b of the same connector 2, and a contact carrier 16.
[0073] The protective cover 4 is a generally rectangular component made of an insulating material with a relative permittivity higher than that of air. More specifically, the protective cover 4 can be an overmolded component 18, such as... Figures 1 to 4 As shown in the embodiments.
[0074] The contact carrier 16 is also a generally rectangular component made of an insulating material with a relative permittivity higher than that of air. The contact carrier 16 includes a contact head 20 with a cross-sectional area smaller than that of the protective cover 4 and a protrusion 22 with a cross-sectional area equal to that of the protective cover 4. The contact carrier 16 may also include a stepped transition between the contact head 20 and the protrusion 22.
[0075] The first conductor 6a and the second conductor 6b extend parallel to each other through the shielded cable 10. At one end, the first conductor 6a and the second conductor 6b each include a terminal portion 24 that protrudes from the shielded cable 10 in the transmission direction T and extends into the protective cover 4.
[0076] The first contact element 12a and the second contact element 12b extend parallel to each other through the contact carrier 16 and into the protective cover 4 in a direction opposite to the transmission direction T.
[0077] like Figure 1 and Figure 3 As shown, the first contact element 12a and the second contact element 12b can each be a conductive spring beam 26, which extends flatly along the transmission direction T. The spring beams 26 can be spaced apart from each other. Each spring beam 26 includes a contact portion 28 at one end, a connecting portion 30 at the opposite end, and a retaining portion 32 between the contact portion 28 and the connecting portion 30.
[0078] The contact portion 28 may have a curved end 34. The curved end 34 may be a pin-shaped or arc-shaped component integrally formed from the material of the corresponding spring beam 26.
[0079] The connecting portion 30 may include a connecting protrusion 36, which protrudes in the opposite direction to the transmission direction T, as a continuation of the spring beam 26. The connecting protrusion 36 may be a plate-like component integrally formed from the material of the corresponding spring beam 26 and fixedly embedded within the protective cover 4.
[0080] The retaining portion 32 can be a straight section of the corresponding spring beam 26 that is fixedly held by the contact carrier 16.
[0081] like Figure 1 and Figure 2 As shown, the first signal path 38a is formed by the first wire 6a and the first contact element 12a, while the second signal path 38b is formed by the second wire 6b and the second contact element 12b. More specifically, at the first engagement position 42a, the terminal portion 24 of the first wire 6a is overlapped and engaged with the engagement protrusion 36 of the first contact element 12a, and at the second engagement position 42b, the terminal portion 24 of the second wire 6b is overlapped and engaged with the engagement protrusion 36 of the second contact element 12b.
[0082] The first engagement position 42a and the second engagement position 42b each have a cross-sectional area perpendicular to the transmission direction T, which is larger than the cross-sectional area of the first conductor 6a, the second conductor 6b, the first contact element 12a, or the second contact element 12b. Therefore, the first engagement position 42a and the second engagement position 42b respectively affect the impedance of the first signal path 38a and the second signal path 38b. Furthermore, the first engagement position 42a and the second engagement position 42b are aligned and located within the protective cover 4. Due to its role as a dielectric material, the insulating material of the protective cover 4 surrounding the first signal path 38a and the second signal path 38b also affects the impedance of the first signal path 38a and the second signal path 38b. To compensate for the aforementioned effects on the first engagement position 42a, the second engagement position 42b, and the protective cover 4, at least one impedance control structure 46 can be implemented on the protective cover 4.
[0083] For example, at least one impedance control structure 46 may be at least one recess 44, locally formed on the outer surface 40 of the protective cover 4, in the region where the first signal path 38a and the second signal path 38b are surrounded by the insulating material of the protective cover 4, and the first signal path 38a and the second signal path 38b have enlarged cross-sections. In particular, at least one recess 44 may create air-filled spaces in said region. For this purpose, at least one recess 44 may be a generally cuboid, cylindrical, conical, hemispherical, trapezoidal, or field-shaped cut in the insulating material of the protective cover 4. The cut may extend at least partially toward the first signal path 38a and / or the second signal path 38b. Additionally, the cut may extend at least along the entire length of the first engagement position 42a and / or the second engagement position 42b in another direction, preferably the transmission direction T.
[0084] Additionally or alternatively, the protective cover 4 may include a lead-through hole 48 as an impedance control structure 46, which extends through the insulating material of the protective cover 4 as a cavity 50 in a generally motion field shape. More specifically, the lead-through hole 48 may extend in a direction perpendicular to the transmission direction T, connecting the top surface 54 of the protective cover 4 to the bottom surface 56 of the protective cover 4. Furthermore, the lead-through hole 48 may extend between a first engagement position 42a and a second engagement position 42b, forming an air-filled gap 58 prior to it.
[0085] like Figure 3 and Figure 4 As shown, the lead through-hole 48 can alternatively extend through the insulating material of the protective cover 4 as a generally cuboid cavity 52. In this embodiment, the lead through-hole 48 can also extend in a direction perpendicular to the transmission direction T, connecting the top surface 54 of the protective cover 4 to the bottom surface 56 of the protective cover 4. Furthermore, the lead through-hole 48 can extend between the first engagement position 42a and the second engagement position 42b, forming an air-filled gap 58 therebetween.
[0086] As from Figure 3 and Figure 4 Furthermore, the protective cover 4 may include a pair of lateral recesses 60 as an impedance control structure 46, which can be implemented as an addition to or replacement of the lead via 48. Specifically, the pair of lateral recesses 60 may extend symmetrically on two opposing side surfaces 62 of the protective cover 4, preferably perpendicularly spanning the two side surfaces 62 between the top surface 54 and the bottom surface 56. Additionally, each of the pair of lateral recesses 60 may extend at least along the entire length of the first engagement position 42a and the second engagement position 42b in the transmission direction T. Furthermore, in a direction parallel to the lead via 48, the pair of lateral recesses 60 may extend along the entire length of the lead via 48.
[0087] More specifically, each of the pair of lateral recesses 60 may be a trapezoidal cutout 64 in the insulating material of the protective cover 4, extending perpendicular to the transmission direction T and parallel to the lead through-hole 48. The cutout 64 may preferably extend along the entire height of the corresponding side surface 62, a height measured in a direction perpendicular to the transmission direction T and parallel to the lead through-hole 48. Due to the trapezoidal shape of the cutout 64, each of the pair of lateral recesses 60 may have two chamfered edges 66 aligned along the transmission direction T.
[0088] Figure 5 and Figure 6 An alternative embodiment of the protective cover 4 is shown, comprising two parts 68 joined together to form the protective cover 4. More specifically, the protective cover 4 may be formed from a pair of prefabricated cover halves 70 that engage in a form-fitting manner. Preferably, due to their hermaphroditic design, the cover halves 70 are identical to each other and include a latching mechanism 72, wherein two latching cams 74 and two latching recesses 76 are aligned on each of the cover halves 70. The latching cams 74 project away from the respective cover halves 70 in a direction perpendicular to the transport direction T and are each configured to engage with one of the two latching recesses on the corresponding other cover half 70 to form a latching connection. For this purpose, the shape of each latching recess is complementary to the shape of the corresponding latching cam 74.
[0089] The cover halves 70 may include an impedance control structure 46, wherein a high dielectric constant insulating material is used to form at least a portion of each cover half 70. Preferably, an insulating material doped with ceramic powder can be used as the high dielectric constant insulating material.
[0090] Each of the two cover halves 70 may further include an inner wall 78, which is at least partially spaced from the first signal path 38a and the second signal path 38b. The inner wall 78 may also be formed in the overmolded member 18, such as... Figures 1 to 4 As shown.
[0091] Figure 7 Another possible embodiment of the impedance control structure 46 is shown, wherein the pair of prefabricated cover halves 70 are surrounded by two capacitive elements 80. More specifically, the two capacitive elements 80 are two metal clips 82, each made of bent sheet metal 84. The metal clips respectively include a top plate 86, a middle plate 88, and a bottom plate 90 arranged in a U-shape.
[0092] More specifically, the top plate 86 and the bottom plate 90 abut against and are in direct contact with the pair of prefabricated cover halves 70. The middle plate 88 may be divided into at least two segments, which are embedded in corresponding retaining grooves 92 on the side surfaces 62 of the pair of prefabricated cover halves 70.
[0093] Alternatively, the capacitor element 80 may be a separate metal plate (not shown) disposed in or glued to a retaining groove 92 on at least one outer surface of the protective cover 4. Additionally, the capacitor element 80 may be a braided metal piece (not shown) surrounding the pair of prefabricated cover halves 70.
[0094] As from Figures 1 to 7 As can be seen, the contact carrier 16 and the protective cover 4 can be arranged adjacent to each other in the transmission direction T and joined in a form-fitting manner. For this purpose, the protective cover 4 may include two protrusions 94 that project toward the contact carrier 16 away from the protective cover 4. The contact carrier 16 may include two complementary grooves, each configured to receive one of the two protrusions 94 of the protective cover 4.
[0095] The arrangement of the protrusion 94 and the groove 96 can also be reversed, i.e., the contact carrier 16 includes the protrusion 94, while the protective cover 4 includes the groove 96.
[0096] Figure 8 A cross-sectional view of a connector 2 for high-frequency data transmission is shown, which includes a cover assembly 1 and a terminal shield 98, wherein the protective cover 4 of the cover assembly 1 and the contact carrier 16 are located within the terminal shield 98. The terminal shield 98 may include an insertion opening 100 for receiving a mating connector 102.
[0097] Connector 2 can also be connected to shielded cable 10, preferably via crimp connection. For this purpose, terminal shield 98 may also include a crimp portion 104 at the end opposite to the insertion opening 100. The crimp portion 104 may be formed as an integral part of terminal shield 98 and extend coaxially with shielded cable 10. Additionally, the crimp portion 104 may be wound around shielded cable in the circumferential direction C, such as from... Figure 8 and Figure 9 visible.
[0098] exist Figure 10The image shows the result of providing a first contact element 12a and a second contact element 12b in a 360° accessible orientation according to an embodiment of the method disclosed in the present invention. The first contact element 12a and the second contact element 12b are configured in a 360° accessible orientation, wherein the engagement protrusion 36 of the first contact element 12a and the engagement protrusion 36 of the second contact element 12b protrude freely away from the contact carrier 16.
[0099] exist Figure 11 The image shows the result of providing a first conductor 6a in a 360° accessible orientation and a second conductor 6b in a 360° accessible orientation according to an embodiment of the method disclosed in the present invention. The first conductor 6a and the second conductor 6b are configured in a 360° accessible orientation, wherein the terminal portion 24 of the first conductor 6a and the terminal portion 24 of the second conductor 6b protrude freely away from the shielded cable 10.
[0100] exist Figure 12 The diagram illustrates the preparation steps of surrounding a first signal path 38a and a second signal path 38b with a casting 106 according to an embodiment of the method disclosed in the present invention. Specifically, the terminal portion 24 of the first conductor 6a is overlappedly bonded to the engagement protrusion 36 of the first contact element 12a at a first engagement position 42a. The terminal portion 24 of the second conductor 6b is overlappedly bonded to the engagement protrusion 36 of the second contact element 12b at a second engagement position 42b.
[0101] In addition, Figure 12 The image shows a casting 106 comprising two mold halves 108a, 108b, two cores 110, and a blade 112, prepared to surround a first engagement position 42a and a second engagement position 42b. Specifically, the blade 112 can be inserted between the first engagement position 42a and the second engagement position 42b. The blade 112 can be disposed on the two cores 110, fixing the first engagement position 42a and the second engagement position 42b from two opposite directions perpendicular to the transmission direction T. The two cores 110 and the blade 112 preferably have a combined shape corresponding to the negative shape of the lead through-hole 48. Therefore, the two cores 110 and the blade 112 can jointly form the lead through-hole 48 in the insulating material of the protective cover 4.
[0102] Figure 1 The result of removing casting 106 after the injected insulating material has hardened is shown. More specifically, insulating material is injected into casting 106 around the first bonding location 42a and the second bonding location 42b. After the injected insulating material has hardened, casting 106 is removed, resulting in a protective cap 4, which is formed as a covered molded part 18 having at least one impedance control structure 46 (i.e., lead through-hole 48).
[0103] Figure Labels
[0104] 1. Cover component
[0105] 2 connectors
[0106] 4. Protective cover
[0107] 5. Electrical conductors
[0108] 6. Electrical wires
[0109] 6a First conductor
[0110] 6b Second conductor
[0111] 10 Shielded Cable
[0112] 12 Contact elements
[0113] 12a First contact element
[0114] 12b Second contact element
[0115] 16 Contact Carrier
[0116] 18 Overmolded components
[0117] 20 Touch the head
[0118] 22. Protrusion
[0119] 24-terminal section
[0120] 26 Spring Beam
[0121] 28 Contact section
[0122] 30. Combination Part
[0123] 32. Retaining part
[0124] 34. Curved end
[0125] 36. Connecting convex part
[0126] 38 Signal Path
[0127] 38a First signal path
[0128] 38b Second Signal Path
[0129] 40 Outer surface
[0130] 42. Combination position
[0131] 42a First binding position
[0132] 42b Second binding position
[0133] 44 recess
[0134] 46 Impedance Control Structure
[0135] 48 Through-hole
[0136] 50 Sports Field Cavities
[0137] 52. Rectangular cavity
[0138] 54 Top surface
[0139] 56 Bottom surface
[0140] 58. Air-filled gaps
[0141] 60 Lateral concave portion
[0142] 62 side surfaces
[0143] 64 Incisions
[0144] 66. Chamfered edges
[0145] 68 parts
[0146] 70 Prefabricated cover half
[0147] 72. Latch mechanism
[0148] 74 Latch Cam
[0149] 76 Latch Groove
[0150] 78 Inner Wall
[0151] 80 Capacitor Components
[0152] 82 Metal Clip
[0153] 84. Bent sheet metal parts
[0154] 86 Top Plate
[0155] 88 mid plate
[0156] 90 base plate
[0157] 92. Maintain the groove.
[0158] 94 convex plates
[0159] 96 slots
[0160] 98-terminal shielding
[0161] 100 Insertion opening
[0162] 102 mating connector
[0163] 104 Crimping Part
[0164] 106 castings
[0165] 108 Mold halves (a, b)
[0166] 110 cores
[0167] 112 blades
[0168] T transmission direction
[0169] C. Circumferential direction
Claims
1. A cover assembly (1) comprising a protective cover (4) and at least two electrical conductors (5) for conducting electrical signals for high-frequency data transmission, wherein, The at least two electrical conductors (5) extend through the protective cover (4) in the transmission direction (T) and are joined together overlappingly at at least one joining position (42) located within the protective cover (4); and wherein, The protective cover (4) includes at least one impedance control structure (46) configured to adjust the impedance of the at least one engagement position (42) to a predetermined value. The cover assembly (1) further includes a contact carrier (16) for supporting at least one of the at least two electrical conductors (5) and configured to be adjacent to each other and form-fitted with the protective cover (4) in the transmission direction, wherein one end of the electrical conductor (5) protrudes from the contact carrier (16) into the protective cover (4).
2. The cover assembly (1) according to claim 1, wherein, One of the at least two electrical conductors (5) is a wire (6) of a shielded cable (10); wherein, The other of the at least two electrical conductors (5) is a pin-shaped contact element (12); and wherein, The wire (6) and the contact element (12) together form a signal path (38) for data transmission.
3. The cover assembly (1) according to claim 2, wherein, The cover assembly (1) includes a first wire (6a), a second wire (6b), a first contact element (12a), and a second contact element (12b); wherein, The first conductor (6a) and the first contact element (12a) together form the first signal path (38a); wherein The second conductor (6b) and the second contact element (12b) together form the second signal path (38b); and wherein The first signal path (38a) and the second signal path (38b) form a pair of signal paths (38).
4. The cover assembly (1) according to claim 3, wherein, The center lines of the pair of signal paths (38) travel parallel to each other along the entire length of the cover assembly (1).
5. The cover assembly (1) according to any one of claims 1 to 4, wherein, The protective cover (4) is molded over at least one mating position (42) and is made of insulating material.
6. The cover assembly (1) according to any one of claims 1 to 4, wherein, The protective cover (4) includes at least two parts (68) that are connected to each other to form the protective cover (4).
7. The cover assembly (1) according to any one of claims 1 to 4, wherein, The at least one impedance control structure (46) includes at least one recess (44) on the outer surface (40) of the protective cover (4).
8. The cover assembly (1) according to claim 3, wherein, The at least one impedance control structure (46) includes at least one lead through-hole (48) in the protective cover (4) extending between the pair of signal paths (38).
9. The cover assembly (1) according to any one of claims 1 to 4, 8, wherein, The at least one impedance control structure (46) includes at least one lateral recess (60) on the side surface (62) of the protective cover (4).
10. The cover assembly (1) according to any one of claims 1 to 4, 8, wherein, The at least one impedance control structure (46) includes at least one capacitor element (80) located on at least one outer surface (40) of the protective cover (4).
11. The cover assembly (1) according to any one of claims 1 to 4, 8, wherein, The at least one impedance control structure (46) includes the use of a high dielectric constant insulating material for the protective cover (4).
12. The cover assembly (1) according to any one of claims 1 to 4, 8, wherein, The at least one impedance control structure (46) is aligned with the at least one coupling position (42).
13. A connector (2) comprising a cover assembly (1) according to any one of claims 1 to 12, a terminal shield (98), and a contact carrier (16), wherein, The protective cover (4) of the cover assembly (1) and the contact carrier (16) are located inside the terminal shield (98); and wherein, The terminal shield (98) includes at least one insertion opening (100) for receiving a mating connector (102).
14. A method for molding a connection (42) between at least one contact element (12) and at least one conductor (6) of a cable (10) using an insulating material, comprising the steps of: Provide the at least one contact element (12); Provide at least one wire (6); The at least one contact element (12) and the at least one wire (6) are positioned in a partially overlapping location; The at least one contact element (12) and the at least one wire (6) are joined at the joint. The joint (42) is surrounded by a casting (106) including a core. Injecting the insulating material into the casting (106); and After the injected insulating material has hardened, the casting (106) and the core (110) are removed, the core forming an impedance control structure in the insulating material.