An integrated ultra-small coupler

Abstract

The present invention belongs to the technical field of signal transmission components, and in particular provides an integrated ultra-small coupler. The coupler mainly includes a protective cover, a bus, a sub-line, a housing, and a circuit board assembly. The coupler uses chip resistors to replace metal film resistors, and optimizes the overall layout of the circuit board assembly by changing the position of the resistor corresponding to the pad, and optimizes the circuit board process technology, greatly reducing the length and height of the circuit board assembly; the sealing effect is achieved by filling the seam between the protective cover and the cable with sealant after heat shrinkage, greatly shortening the length of the protective cover; the impact and vibration resistance of the components are improved by encapsulating the gap between the inner wall of the housing and the circuit board assembly; the temperature resistance of the components is improved by assembling thermal insulation gaskets.

Description

Technical Field

[0001] The invention belongs to the technical field of signal transmission elements, and in particular provides an integrated ultra-small coupler. Background Art

[0002] With the development of science and technology and the opening of the air transport market, the functions of aircraft onboard systems are becoming more and more comprehensive. The functions of onboard systems are gradually increasing with the demand, which leads to an increase in related equipment of onboard systems. However, the internal space of the aircraft is limited, and there are strict requirements on the weight of components. In order to increase the functions and equipment of aircraft onboard systems without affecting the flight performance of the aircraft, the integration and miniaturization of component products have become the general direction of market development.

[0003] Data bus couplers are components that are used in large quantities in airborne systems. Currently, the widely used data bus couplers on the market still have room for improvement in integration and miniaturization. Therefore, a more integrated and miniaturized coupler is needed to improve the space utilization of airborne systems. Summary of the invention

[0004] In order to solve the above problems, the present invention provides an integrated coupler with a smaller volume.

[0005] To achieve the above object, the technical solution adopted by the present invention is: an integrated ultra-small coupler, including a protective cover, a bus, a sub-line, a shell, and a circuit board assembly, the circuit board assembly is assembled inside the shell, the protective cover is sleeved on the outside of the shell, the number of the bus is two, one bus is welded separately to one side of the circuit board assembly, and the other bus and the sub-line are welded to the other side of the circuit board assembly;

[0006] The circuit board assembly includes a circuit board, an embedding hole, a coil, a chip resistor, a coil pad, a circuit pad, a printed copper wire, and a coil conductor. The embedding hole is opened in the middle of the circuit board, the coil is fixed in the embedding hole, there are six circuit pads in total, two circuit pads are arranged on one side of a separate bus of the circuit board, four circuit pads are arranged on the other side of the circuit board, four coil pads are all arranged on the surface of the circuit board, and the four coil pads are evenly distributed on the periphery of the embedding hole, two chip resistors are fixed on the surface of the circuit board, the printed copper wire is printed on the surface of the circuit board, and the coil conductor is welded between the coil and the coil pad.

[0007] Furthermore, the four circuit pads and chip resistors corresponding to the two buses are connected in a circuit pad-chip resistor-circuit pad manner through printed copper wires, the two chip resistors are respectively connected to the two coil pads corresponding to the secondary terminals of the coil through printed copper wires, and the two circuit pads corresponding to the sub-lines are respectively connected to the two coil pads corresponding to the primary terminals of the coil.

[0008] Furthermore, the shell includes a shell body, threading holes, and a wire locking structure. The three threading holes are respectively opened on the end surface of the shell body, and the inner walls of the threading holes are embedded with the wire locking structure.

[0009] Furthermore, the shell also includes a thermal insulation gasket, and two thermal insulation gaskets are respectively arranged on the upper and lower sides of the inner cavity of the shell body, and the circuit board assembly is fixed between the two thermal insulation gaskets.

[0010] Furthermore, both ends of the inner wall of the protective sleeve are filled with sealant.

[0011] Furthermore, potting glue is filled between the inner wall of the shell and the circuit board assembly.

[0012] The beneficial effects of using the present invention are:

[0013] 1. Use chip resistors instead of metal film resistors, optimize the overall layout of the circuit board components by changing the position of the resistor corresponding to the pad, and optimize the circuit board manufacturing process, greatly reducing the length and height of the circuit board components;

[0014] 2. The sealing effect is achieved by filling the seam between the protective sleeve and the cable with sealant after heat shrinkage, which greatly shortens the length of the protective sleeve;

[0015] 3. The impact and vibration resistance of components is improved by encapsulating the gap between the inner wall of the shell and the circuit board components;

[0016] 4. Improve the temperature resistance of components by installing thermal insulation gaskets. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the internal structure of the present invention;

[0018] Figure 2 It is a schematic diagram of the external structure of the present invention;

[0019] Figure 3 A top view of a circuit board assembly of the present invention;

[0020] Figure 4 This is a bottom view of the circuit board assembly of the present invention.

[0021] The reference numerals include: 1-protective cover; 2-bus; 3-sub-line; 4-shell; 401-shell body; 402-threading hole; 403-locking structure; 404-thermal insulation gasket; 5-circuit board assembly; 501-circuit board; 502-embedded hole; 503-coil; 504-chip resistor; 505-coil pad; 506-line pad; 507-printed copper wire; 508-coil conductor; 6-sealant. DETAILED DESCRIPTION

[0022] The present invention is described in detail below with reference to the accompanying drawings.

[0023] Reference Figure 1-Figure 4 An integrated ultra-small coupler includes a protective cover 1, a bus 2, a sub-line 3, a housing 4, and a circuit board assembly 5. The circuit board assembly 5 is assembled inside the housing 4, and the protective cover 1 is sleeved on the outside of the housing 4. There are two buses 2, one bus 2 is welded to one side of the circuit board assembly 5, and the other bus 2 and the sub-line 3 are welded to the other side of the circuit board assembly 5;

[0024] The circuit board assembly 5 includes a circuit board 501, an embedding hole 502, a coil 503, a chip resistor 504, a coil pad 505, a circuit pad 506, a printed copper wire 507, and a coil conductor 508. The embedding hole 502 is opened in the middle of the circuit board 501, the coil 503 is fixed in the embedding hole 502, there are six circuit pads 506, two circuit pads 506 are arranged on one side of the separate bus 2 of the circuit board 501, and four circuit pads 506 are arranged on the other side of the circuit board 501. The four coil pads 505 are all arranged on the surface of the circuit board 501, and the four coil pads 505 are evenly distributed on the periphery of the embedding hole 502. The two chip resistors 504 are fixed on the surface of the circuit board 501, the printed copper wire 507 is printed on the surface of the circuit board 501, and the coil conductor 508 is welded between the coil 503 and the coil pad 505.

[0025] Preferably, the protective sleeve 1 is made of heat shrinkable material.

[0026] Preferably, the two bus lines 2 and one sub-line 3 are twisted-pair shielded cables, and the shielding layer is welded on the housing 4 .

[0027] Preferably, the circuit board 501 is an epoxy glass cloth board, and the characteristic impedance of the circuit board 501 is 77Ω.

[0028] The four circuit pads 506 and the chip resistors 504 corresponding to the two buses 2 are connected in the manner of circuit pad 506-chip resistor 504-circuit pad 506 through printed copper wires 507. The two chip resistors 504 are respectively connected to the two coil pads 505 corresponding to the secondary terminals of the coil 503 through the printed copper wires 507, and the two circuit pads 506 corresponding to the sub-line 3 are respectively connected to the two coil pads 505 corresponding to the primary terminals of the coil 503.

[0029] The resistors used in the existing data bus coupler are mainly fixed metal film resistors. At the same time, due to the volume and working environment requirements of the fixed metal film resistors, the layout of the circuit board is loose. This design replaces the metal film resistors with chip resistors 504, which greatly reduces the space occupied by the resistor elements. After using the chip resistors 504, the two resistor elements can be arranged radially in parallel (different from the axial layout of the metal film resistors. Because the metal film resistors are longer, if the two metal film resistors are radially arranged in parallel, the width is much larger than the coil width, so the metal film resistors are generally arranged axially). By changing the position of the resistor corresponding to the pad, the overall layout of the circuit board assembly 5 is optimized, and the circuit board manufacturing process is optimized, which greatly reduces the length and height of the circuit board assembly 5.

[0030] The housing 4 includes a housing body 401 , threading holes 402 , and a wire locking structure 403 . The three threading holes 402 are respectively opened on the end surface of the housing body 401 , and the inner walls of the threading holes 402 are embedded with the wire locking structures 403 .

[0031] Preferably, the shell body 401 of the shell 4 adopts a symmetrical split structure, and the two halves of the split shell body 401 are fixed by soldering.

[0032] The housing 4 further includes a heat-insulating gasket 404 . Two heat-insulating gaskets 404 are respectively disposed on the upper and lower sides of the inner cavity of the housing body 401 . The circuit board assembly 5 is fixed between the two heat-insulating gaskets 404 .

[0033] Preferably, the thermal insulation gasket 404 is made of a relatively soft thermal insulation material, which can assist the potting material in playing a buffering role.

[0034] Both ends of the inner wall of the protective sleeve 1 are filled with sealant 6 .

[0035] Preferably, the sealant 6 is a modified two-component silicone sealant.

[0036] The protective cover of the existing data bus coupler needs to extend a certain length to wrap the joint between the shell and the cable to achieve the purpose of sealing. The protective cover 1 used in this design is slightly longer than the shell 4. The sealing effect is achieved by filling the sealant 6 at the joint between the protective cover 1 and the cable after heat shrinkage, which greatly shortens the length of the protective cover 1.

[0037] The length, width and height ratio of the existing general data bus coupler is 65:14:11, and the length, width and height ratio of the improved data bus coupler in this design is 25:13:7.

[0038] The space between the inner wall of the housing 4 and the circuit board assembly 5 is filled with potting glue.

[0039] The above contents are only preferred embodiments of the present invention. For ordinary technicians in this field, many changes can be made in the specific implementation methods and application scopes based on the ideas of the present invention. As long as these changes do not deviate from the concept of the present invention, they all belong to the protection scope of the present invention.

Claims

1. An integrated ultra-small coupler, characterized in that: It includes a protective cover, a bus, a sub-line, a housing, and a circuit board assembly. The circuit board assembly is assembled inside the housing, and the protective cover is sleeved on the outside of the housing. There are two buses, one bus is welded to one side of the circuit board assembly, and the other bus and the sub-line are welded to the other side of the circuit board assembly. The circuit board assembly includes a circuit board, an embedded hole, a coil, a chip resistor, a coil pad, a circuit pad, a printed copper wire, and a coil conductor. The embedded hole is opened in the middle of the circuit board, the coil is fixed in the embedded hole, there are six circuit pads in total, two circuit pads are arranged on one side of a separate bus of the circuit board, four circuit pads are arranged on the other side of the circuit board, four coil pads are arranged on the surface of the circuit board, and the four coil pads are evenly distributed on the periphery of the embedded hole, two chip resistors are fixed on the surface of the circuit board, the printed copper wire is printed on the surface of the circuit board, and the coil conductor is welded between the coil and the coil pad; The two chip resistors are radially arranged in parallel; The protective sleeve is made of heat-shrinkable material, and the length of the protective sleeve is slightly longer than the shell. The sealing effect is achieved by filling the seam between the protective sleeve and the cable with sealant after heat shrinkage, which greatly shortens the length of the protective sleeve. The length, width and height ratio of the shell is 25:13:

7.

2. An integrated ultra-small coupler according to claim 1, characterized in that: The four circuit pads and chip resistors corresponding to the two buses are connected in a circuit pad-chip resistor-circuit pad manner through printed copper wires. The two chip resistors are respectively connected to the two coil pads corresponding to the secondary terminals of the coil through printed copper wires, and the two circuit pads corresponding to the sub-lines are respectively connected to the two coil pads corresponding to the primary terminals of the coil.

3. An integrated ultra-small coupler according to claim 1, characterized in that: The shell comprises a shell body, threading holes and a wire locking structure. The three threading holes are respectively arranged on the end surface of the shell body, and the inner walls of the threading holes are embedded with the wire locking structures.

4. An integrated ultra-small coupler according to claim 3, characterized in that: The shell also includes a heat-insulating gasket, and two heat-insulating gaskets are respectively arranged on the upper and lower sides of the inner cavity of the shell body, and the circuit board assembly is fixed between the two heat-insulating gaskets.

5. The integrated ultra-small coupler according to claim 1, characterized in that: Both ends of the inner wall of the protective sleeve are filled with sealant.

6. The integrated ultra-small coupler according to claim 1, characterized in that: The space between the inner wall of the shell and the circuit board assembly is filled with potting glue.

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