Electric connector structure and manufacturing method thereof

Abstract

The invention provides an electric connector structure and a manufacturing method thereof, and the structure comprises a plurality of cables which comprise a plurality of long front-row cables and a plurality of short rear-row cables, and the front-row cables and the rear-row cables are arranged in a staggered manner; the wire frame group is formed outside the plurality of cables and enables a preset distance to be formed between the adjacent front row of cables and the rear row of cables; at least one surface of the circuit board is provided with a plurality of front-row welding pad groups for welding wire cores of the plurality of front-row cables at the front side of the coil holder group and a plurality of rear-row welding pad groups for welding wire cores of the plurality of rear-row cables, and the other side, opposite to the plurality of rear-row welding pad groups, of the plurality of front-row welding pad groups is provided with a plurality of contacts; and the front-row welding pad group and the rear-row welding pad group are arranged in a staggered manner.

Description

Technical Field

[0001] This invention relates to an electrical connector structure and its manufacturing method, particularly to an electrical connector in which multiple front-row cables and multiple rear-row cables are arranged alternately on a circuit board to improve the problem of far-end crosstalk (FEXT) when transmitting high-frequency signals; furthermore, a wire frame assembly formed on the outside of the multiple cables can provide a fixed spacing between the front-row cables and the rear-row cables to reduce the coupling effect between adjacent cables, thereby improving the problems of near-end crosstalk (NEXT) and far-end crosstalk. Background Technology

[0002] To maintain optimal electrical characteristics when cables are coupled to electronic devices, it is necessary to avoid system impedance discontinuities in order to maintain a fixed impedance. Setting up an electrical connector between the cable and the electronic device will create discontinuities in impedance at the connection point, which will further lead to insertion loss, which reduces signal strength, and return loss, which causes the signal to be reflected back to the signal source.

[0003] As mentioned above, insertion loss is related to cable length and the number of connection points; the longer the cable or the more connection points, the greater the loss. Reflection loss, on the other hand, refers to the energy reflected back to the signal source during signal transmission within a conductor due to impedance mismatch or discontinuity. These parameters have a significant impact on the transmission speed, integrity, and reliability of high-frequency signals.

[0004] Furthermore, in high-frequency applications, near-end crosstalk (NEXT) and far-end crosstalk (FEXT) are two common problems. Near-end crosstalk refers to interference signals coupling to adjacent cables near the signal source, affecting signal integrity. Far-end crosstalk refers to interference signals coupling to adjacent cables near the signal receiver, causing signal distortion. The impact of far-end crosstalk is generally greater than that of near-end crosstalk because its cumulative interference signal energy increases with cable length. Due to these issues when cables are coupled to electrical connectors, those in this industry need to address them through optimized connector structures. Summary of the Invention

[0005] Therefore, in view of the above-mentioned problems and deficiencies, the main objective of the present invention is to provide an electrical connector structure and a method for manufacturing the same.

[0006] This invention provides an electrical connector structure, characterized in that it includes an insulating body, and inside the insulating body are:

[0007] The plurality of cables includes a plurality of front-row cables of longer length and a plurality of rear-row cables of shorter length, wherein the front-row cables and the rear-row cables are arranged in an alternating pattern.

[0008] A single-line cable tray is formed on the outside of the plurality of cables, creating a predetermined spacing between adjacent front and rear rows of cables; and

[0009] A circuit board has at least one surface provided with a plurality of front row solder pads for soldering the cores of a plurality of front row cables on the front side of a cable tray assembly, and a plurality of rear row solder pads for soldering the cores of a plurality of rear row cables. A plurality of contacts are provided on the other side of the plurality of front row solder pads opposite to the plurality of rear row solder pads, and the front row solder pads and the rear row solder pads are arranged in an alternating manner. The alternating arrangement of the plurality of front row cables and the plurality of rear row cables on the circuit board improves the far-end crosstalk problem when transmitting high-frequency signals.

[0010] The electrical connector structure includes an upper cable frame and a lower cable frame that can be joined together by a latch and a slot. A plurality of positioning slots are provided on the opposite outer sides of the upper cable frame and the lower cable frame. A plurality of protrusions are provided on the plurality of positioning slots for positioning a grounding piece by a plurality of fastening slots. The protrusions are deformed and expanded at their top ends by heating and pressing to fix the grounding piece, so that the grounding piece is fixed on the opposite outer sides of both the upper cable frame and the lower cable frame.

[0011] The electrical connector structure includes: one side of the grounding piece includes a plurality of fixing parts having the retaining groove inside, and the other side includes a plurality of welding parts that bend downward and extend downward, and each welding part has at least one grounding foot welded to the front row of solder pads at its end.

[0012] The aforementioned electrical connector structure includes: both the front and rear cables have four cores, namely two signal cores located in the center and two grounding cores located on the outer sides; the front and rear pad groups of the circuit board also form four parallel pads corresponding to the cores of the front and rear cables, and the width of the four parallel front pad groups at the two outer positions is greater than the width at the two central positions; the two grounding cores and the grounding pins of the grounding plate are simultaneously coupled to the two outer positions of the front pad groups.

[0013] The electrical connector structure, wherein: the insulating body includes an outer seat and an inner seat that are joined together, the outer seat is for the circuit board to be snapped and fixed, and the inner seat, for the wire frame assembly to be fixed, is fixed inside the outer seat by a snap-fit ​​and a fixing groove of the outer seat and by an in-mold injection molding process.

[0014] The electrical connector structure, wherein: the top side of the outer seat of the insulating body is provided with a receiving groove, and the receiving groove houses a locking spring piece made of a metal plate, and the top side of the locking spring piece has a lacing hole, and a pull strap for unlocking is installed in the lacing hole.

[0015] A method for manufacturing an electrical connector, characterized by comprising the following steps:

[0016] S1. A plurality of cables are provided, including a plurality of front-row cables of longer length and a plurality of rear-row cables of shorter length, wherein the front-row cables and the rear-row cables are arranged in an alternating pattern.

[0017] S2. The multiple cables are formed into a frame assembly by plastic injection molding on the outside;

[0018] S3. Bend the multiple front-row cables on the front side of the cable tray to create a clearance, and strip the multiple rear-row cables to expose the multiple wire cores.

[0019] S4. Strip the multiple front-row cables that have been avoided to expose the multiple wire cores;

[0020] S5. First, the plurality of rear row cables are soldered onto the plurality of rear row pads on a circuit board. Then, the plurality of front row cables that have been avoided are reset and soldered onto the plurality of front row pads on the circuit board, and the front row pads and the rear row pads are arranged in an alternating manner.

[0021] The manufacturing method of the electrical connector includes a step S31 between step S3 and step S4: rotating the wire frame assembly by 90 degrees to move the plurality of front row cables to the position for stripping the plurality of rear row cables, and then performing step S4.

[0022] The manufacturing method of the electrical connector further includes step S6: the wire frame assembly includes an upper wire frame and a lower wire frame, and a plurality of protrusions are provided on the opposite outer sides of the upper wire frame and the lower wire frame for positioning the grounding piece by a plurality of snap slots. The protrusions are deformed and expanded at their top ends by heating and pressing to fix the grounding piece, so that the grounding piece is fixed on the opposite outer sides of both the upper wire frame and the lower wire frame.

[0023] The manufacturing method of the electrical connector further includes step S7: inserting the wire frame assembly with the grounding piece already assembled into the outer seat of the insulating body to form a positioning, and making the circuit board engage with the outer seat to form a fixation, and then pushing the inner seat of the insulating body from the rear side of the wire frame assembly, and fixing it to the inside of the outer seat by a snap-fit ​​and fixing groove and in-mold injection molding.

[0024] The method for manufacturing the electrical connector further includes step S8: a locking spring is installed on the top side of the outer seat of the insulating body, and a pull strap is installed on the top side of the locking spring.

[0025] The main advantage of this invention is that the multiple front and rear cables in the electrical connector are arranged alternately on the circuit board to improve the far-end crosstalk problem when transmitting high-frequency signals; furthermore, the wire frame assembly formed on the outside of the multiple cables can provide a fixed spacing between the front and rear cables to reduce the coupling effect between adjacent cables, while improving the problems of near-end and far-end crosstalk of the cables. Attached Figure Description

[0026] Figure 1 This is a perspective view of the electrical connector of the present invention.

[0027] Figure 2 This is a three-dimensional view of the electrical connector of the present invention from another perspective.

[0028] Figure 3 This is an exploded perspective view of the electrical connector of the present invention.

[0029] Figure 4 This is an exploded perspective view of the electrical connector of the present invention.

[0030] Figure 5 This is a side cross-sectional view of the electrical connector of the present invention.

[0031] Figure 6 This is a cross-sectional view of the electrical connector of the present invention from another side.

[0032] Figure 7 This is a more detailed exploded perspective view of the internal components of the electrical connector of the present invention.

[0033] Figure 8 This is a more detailed perspective exploded view of the internal components of the electrical connector of the present invention.

[0034] Figure 9 This is a flowchart illustrating the steps of the electrical connector manufacturing method of the present invention.

[0035] Explanation of reference numerals in the attached diagram: 1-Insulating body; 11-Outer base; 111-Fixing groove; 112-Accommodating groove; 12-Inner base; 121-Snap fastener; 13-Locking spring; 130-Tape hole; 14-Pull strap; 2-Cable; 21-Front row cable; 22-Rear row cable; 23-Signal wire core; 24-Grounding wire core; 3-Wire frame assembly; 31-Upper wire frame; 311-Slot; 312-Positioning groove; 313-Protruding buckle; 32-Lower wire frame; 321-Tick; 322-Positioning groove; 323-Protruding buckle; 4-Circuit board; 41-Front row solder pad assembly; 42 - Rear row solder pad assembly; 43- Contact point; 5- Grounding plate; 51- Fixing part; 510- Clip groove; 52- Welding part; 521- Grounding foot; S1, Provide a plurality of cables with a longer front row and a plurality of shorter rear row, wherein the front row and rear row cables are arranged in an alternating pattern; S2, The plurality of cables are formed into a wire frame assembly by plastic injection molding; S3, Bend the plurality of front row cables on the front side of the wire frame assembly to create clearance, and strip the plurality of rear row cables to expose the multiple wire cores; S31, Rotate the wire frame assembly ninety degrees to make S4. The plurality of front-row cables are rotated to the position for stripping the plurality of rear-row cables; S5. The plurality of front-row cables that have been avoided are stripped to expose the multiple wire cores; S6. The plurality of rear-row cables are first soldered to the plurality of rear-row solder pads on a circuit board, and then the plurality of front-row cables that have been avoided are reset and soldered to the plurality of front-row solder pads on the circuit board, wherein the front-row solder pads and the rear-row solder pads are arranged alternately; S7. The cable frame assembly includes an upper cable frame and a lower cable frame, and a plurality of locking slots for positioning grounding plates are provided on the opposite outer sides of the upper cable frame and the lower cable frame. S7. The multiple protruding buckles are deformed and expanded at the top by heating and pressing to fix the grounding piece, so that the grounding piece is fixed on the opposite outer sides of the upper and lower wire frames; S8. The wire frame assembly with the grounding piece assembled is inserted into the outer seat of the insulating body for positioning, and the circuit board is locked into the outer seat for fixing. Then the inner seat of the insulating body is pushed in from the rear side of the wire frame assembly and fixed to the inside of the outer seat by the buckle, fixing groove and in-mold injection process; S9. A locking spring is installed on the top side of the outer seat of the insulating body and a pull strap is installed on the top side of the locking spring. Detailed Implementation

[0036] To achieve the above objectives and effects, the technical means and structure adopted by the present invention are described in detail below with reference to the accompanying drawings, so as to facilitate a complete understanding.

[0037] Please see Figures 1 to 8The figures shown are, respectively, a three-dimensional appearance view, another perspective three-dimensional appearance view, an exploded three-dimensional view, another perspective exploded three-dimensional view, a side sectional view, another side sectional view, a more detailed exploded three-dimensional view of the internal components, and a more detailed exploded three-dimensional view of the internal components from another perspective. As can be clearly seen from the figures, the present invention provides an electrical connector structure, mainly comprising an insulating body 1, and a plurality of cables 2, a cable frame assembly 3, and a circuit board 4 disposed within the insulating body 1. Its main components and features are detailed below:

[0038] The plurality of cables 2 includes a plurality of longer front-row cables 21 and a plurality of shorter rear-row cables 22, and the front-row cables 21 and the rear-row cables 22 are arranged in an alternating pattern.

[0039] The cable tray assembly 3 is formed on the outside of the plurality of cables 2 and forms a predetermined distance between the adjacent front row cables 21 and the rear row cables 22. The aforementioned cable tray assembly 3 formed on the outside of the plurality of cables 2 can provide a fixed distance between the front row cables 21 and the rear row cables 22 to reduce the coupling effect between adjacent cables 2, and at the same time improve the problems of near-end crosstalk (NEXT) and far-end crosstalk (FEXT) of the cables 2.

[0040] The circuit board 4 has at least one surface provided with a plurality of front row solder pads 41 for soldering the cores (including signal cores 23 and ground cores 24) of the plurality of front row cables 21 on the front side of the cable tray assembly 3, and a plurality of rear row solder pads 42 for soldering the cores (including signal cores 23 and ground cores 24) of the plurality of rear row cables 22. A plurality of contacts 43 are provided on the other side of the plurality of front row solder pads 41 opposite to the plurality of rear row solder pads 42. The plurality of contacts 43 can provide inter-connection connectors (not shown) for corresponding coupling and electronic signal transmission. The front row solder pads 41 and the rear row solder pads 42 are arranged in an alternating manner. The alternating arrangement of the plurality of front row cables 21 and the plurality of rear row cables 22 on the circuit board 4 improves the far-end crosstalk problem when transmitting high-frequency signals.

[0041] The aforementioned insulating body 1 includes an outer seat 11 and an inner seat 12 that are connected to each other. The outer seat 11 is used to snap and fix the circuit board 4, while the inner seat 12, which is used to fix the wire frame assembly 3, is fixed inside the outer seat 11 by a snap 121 and the fixing groove of the outer seat 11 and by an in-mold injection molding process. The spacing between the outer seat 11, the inner seat 12, and the plurality of cables 2 is filled with plastic material to control impedance changes and reduce insertion loss and return loss. The top side of the outer seat 11 of the insulating body 1 is provided with a receiving groove 112, and the receiving groove 112 houses a locking spring piece 13 made of a metal plate. The top side of the locking spring piece 13 has a lacing hole 130, and a pull strap 14 for unlocking is installed in the lacing hole 130.

[0042] The aforementioned cable tray assembly 3 includes an upper cable tray 31 and a lower cable tray 32 that can be connected to each other via a latch 321 and a slot 311. Both the upper cable tray 31 and the lower cable tray 32 are made of integrally molded plastic material. A plurality of positioning slots 312 are provided on the opposite outer sides of the upper cable tray 31 and the lower cable tray 32. Each positioning slot 312 has a plurality of protruding buckles 313 for a plurality of latching slots 510 to be fitted and positioned on it. The protruding buckles 313 are deformed and expanded at their top ends by heat pressing to fix the grounding piece 5. The grounding piece 5 has a flat plate-like structure, so that the grounding piece 5 is fixed on the opposite outer sides of both the upper cable tray 31 and the lower cable tray 32. The grounding plate 5 includes a plurality of fixing parts 51 with the internal groove 510 on one side, and a plurality of welding parts 52 extending downward on the other side. Each welding part 52 has at least one grounding foot 521 welded to the front row of solder pads 41 at its end. The grounding plate 5, which is provided on the opposite outer side of the upper cable tray 31 and the lower cable tray 32, can absorb the electromagnetic waves generated when the cable 2 transmits high-frequency signals. The grounding foot 521 of the grounding plate 5 can guide the current converted by the electromagnetic waves to the front row of solder pads 41 of the circuit board 4, and then guide it from the front row of solder pads 41 to the grounding area of ​​the inner layer of the circuit board 4 or other components for elimination, thereby greatly reducing the electromagnetic interference (EMI) effect.

[0043] The aforementioned front cable 21 and rear cable 22 each include four wire cores: two signal wire cores 23 located in the center and two grounding wire cores 24 located on the outer sides. The front pad group 41 and the rear pad group 42 of the circuit board 4 also form four parallel pads corresponding to the wire cores of the front cable 21 and the rear cable 22. The width of the front pad group 41, which has four parallel pads, is greater on the outer sides than on the center. The two grounding wire cores 24 and the grounding pins 521 of the grounding plate 5 are simultaneously coupled to the outer sides of the front pad group 41.

[0044] in accordance with Figures 1 to 8 The disclosed electrical connector structure is shown in the attached image. Figure 9 The diagram shown is a flowchart of the manufacturing method of the electrical connector of the present invention, which includes the following steps:

[0045] Step S1: Provide a plurality of cables, including a plurality of front-row cables of longer length and a plurality of rear-row cables of shorter length, wherein the front-row cables and the rear-row cables are arranged in an alternating pattern.

[0046] Step S2: The multiple cables are formed into a frame assembly by plastic injection molding.

[0047] Step S3: Bend the multiple front-row cables on the front side of the cable tray to create clearance, and strip the multiple rear-row cables to expose the multiple cores.

[0048] Step S31: Rotate the cable tray assembly by 90 degrees so that the plurality of front row cables are moved to the position for stripping the plurality of rear row cables.

[0049] Step S4: Strip the multiple front-row cables that have been avoided to expose the multiple wire cores.

[0050] Step S5: First, solder the plurality of rear row cables to the plurality of rear row pads on a circuit board. Then, reset the plurality of front row cables that have been avoided and solder them to the plurality of front row pads on the circuit board. The front row pads and the rear row pads are arranged in an alternating pattern.

[0051] Step S6: The wire frame assembly includes an upper wire frame and a lower wire frame. On the opposite outer sides of the upper wire frame and the lower wire frame, there are multiple protrusions for positioning the grounding plate by multiple slots. The multiple protrusions are deformed and expanded at the top by heating and pressing to fix the grounding plate, so that the grounding plate is fixed on the opposite outer sides of the upper wire frame and the lower wire frame.

[0052] Step S7: Insert the wire frame assembly with the grounding piece already assembled into the outer seat of the insulating body for positioning, and fix the circuit board in the outer seat. Then push the inner seat of the insulating body into the wire frame assembly from the rear side, and fix it in the outer seat through the snap-fit, fixing groove and in-mold injection molding process.

[0053] Step S8: A locking spring is installed on the top side of the outer seat of the insulating body, and a pull strap is installed on the top side of the locking spring.

[0054] The main feature of this invention is that the multiple front row cables 21 and multiple rear row cables 22 in the electrical connector are arranged in a staggered manner on the circuit board 4 to improve the far-end crosstalk problem when transmitting high-frequency signals; furthermore, the wire frame assembly 3 formed on the outside of the multiple cables 2 can provide a fixed spacing between the front row cables 21 and the rear row cables 22 to reduce the coupling effect between adjacent cables 2, and at the same time improve the near-end crosstalk and far-end crosstalk problems of the cables 2.

[0055] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Therefore, any simple modifications and equivalent structural changes made based on the description and drawings of the present invention should also be included within the patent scope of the present invention.

Claims

1. An electrical connector structure, characterized in that, It includes an insulating body, and inside the insulating body are: The plurality of cables includes a plurality of front-row cables of longer length and a plurality of rear-row cables of shorter length, wherein the front-row cables and the rear-row cables are arranged in an alternating pattern. A single-line cable tray is formed on the outside of the plurality of cables, creating a predetermined spacing between adjacent front and rear rows of cables; and A circuit board has at least one surface provided with a plurality of front row solder pads for soldering the cores of a plurality of front row cables on the front side of a cable tray assembly, and a plurality of rear row solder pads for soldering the cores of a plurality of rear row cables. A plurality of contacts are provided on the other side of the plurality of front row solder pads opposite to the plurality of rear row solder pads, and the front row solder pads and the rear row solder pads are arranged in an alternating manner. The alternating arrangement of the plurality of front row cables and the plurality of rear row cables on the circuit board improves the far-end crosstalk problem when transmitting high-frequency signals.

2. The electrical connector structure as described in claim 1, characterized in that: The cable tray assembly includes an upper cable tray and a lower cable tray that can be connected to each other by latches and slots. A plurality of positioning slots are provided on the opposite outer sides of the upper cable tray and the lower cable tray, and a plurality of protrusions are provided on the plurality of positioning slots for positioning a grounding plate. The protrusions are deformed and expanded at their top ends by heating and pressing to fix the grounding plate, so that the grounding plate is fixed on the opposite outer sides of the upper cable tray and the lower cable tray.

3. The electrical connector structure as described in claim 2, characterized in that: The grounding plate includes a plurality of fixing parts with the groove inside on one side, and a plurality of welding parts that bend downward on the other side, and each welding part has at least one grounding foot welded to the front row of welding pads at its end.

4. The electrical connector structure as described in claim 1, characterized in that: Both the front and rear cables include four wire cores: two signal wire cores located in the center and two grounding wire cores located on the outer sides. The front and rear pad groups of the circuit board also form four parallel pads corresponding to the wire cores of the front and rear cables. The width of the four parallel front pad groups at the two outer positions is greater than the width at the two center positions. The two grounding wire cores and the grounding pins of the grounding plate are simultaneously coupled to the two outer positions of the front pad groups.

5. The electrical connector structure as described in claim 1, characterized in that: The insulating body includes an outer seat and an inner seat that are joined together. The outer seat is used to snap and fix the circuit board, while the inner seat, which is used to fix the wire frame assembly, is fixed inside the outer seat by a snap-fit ​​and a fixing groove of the outer seat and by an in-mold injection molding process.

6. The electrical connector structure as described in claim 5, characterized in that: The outer base of the insulating body has a receiving groove on its top side, and the receiving groove contains a locking spring piece made of a metal plate. The top side of the locking spring piece has a lacing hole, and a pull strap for unlocking is installed in the lacing hole.

7. A method for manufacturing an electrical connector, characterized in that, It includes the following steps: S1. A plurality of cables are provided, including a plurality of front-row cables of longer length and a plurality of rear-row cables of shorter length, wherein the front-row cables and the rear-row cables are arranged in an alternating pattern. S2. The multiple cables are formed into a frame assembly by plastic injection molding on the outside; S3. Bend the multiple front-row cables on the front side of the cable tray to create a clearance, and strip the multiple rear-row cables to expose the multiple wire cores. S4. Strip the multiple front-row cables that have been avoided to expose the multiple wire cores; S5. First, the plurality of rear row cables are soldered onto the plurality of rear row pads on a circuit board. Then, the plurality of front row cables that have been avoided are reset and soldered onto the plurality of front row pads on the circuit board, and the front row pads and the rear row pads are arranged in an alternating manner.

8. The method for manufacturing an electrical connector as described in claim 7, characterized in that: Between step S3 and step S4, there is also step S31: rotate the cable tray group by 90 degrees so that the plurality of front row cables are moved to the position for stripping the plurality of rear row cables, and then execute step S4.

9. The method for manufacturing an electrical connector as described in claim 7, characterized in that: It also includes step S6: the wire frame assembly includes an upper wire frame and a lower wire frame. On the opposite outer sides of the upper wire frame and the lower wire frame, there are multiple protrusions for positioning the grounding plate by multiple slots. The multiple protrusions are deformed and expanded at the top by heating and pressing to fix the grounding plate, so that the grounding plate is fixed on the opposite outer sides of the upper wire frame and the lower wire frame.

10. The method for manufacturing an electrical connector as described in claim 7, characterized in that: It also includes step S7: inserting the wire frame assembly that has been assembled into the outer seat of the insulating body to form a positioning, and making the circuit board snap into the outer seat to form a fixation, and then pushing the inner seat of the insulating body from the rear side of the wire frame assembly, and fixing it to the inside of the outer seat by means of a snap fastener, a fixing groove and an in-mold injection molding process.

11. The method for manufacturing an electrical connector as described in claim 7, characterized in that: It also includes step S8: a locking spring is installed on the top side of the outer seat of the insulating body, and a pull strap is installed on the top side of the locking spring.

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