High speed differential pair flat cable with modular twisted pair data connectors

Abstract

A differential pair flat cable includes a planar substrate, a signal conductor, a shielding conductor, and exposed signal connection pads. The cable also features slots formed in the planar substrate and the shielding conductor, which receive vertical shielding tabs from an inner shielding terminal to provide mechanical retention and electrical grounding. A connector assembly is mounted to the cable end and includes an inner signal terminal, an inner shielding terminal with vertical tabs, an insulating inner housing, and an outer shielding terminal. This assembly provides a robust, low-loss connection suitable for high-speed data transmission and offers improved signal integrity and electromagnetic compatibility. The design enables easy assembly and reliable performance, making it ideal for a variety of applications, including automotive and industrial networks.

Description

[0001] Cross-reference related applications

[0002] This application claims the benefit of priority to U.S. Patent Application No. 19 / 629,096, filed March 26, 2026, entitled "High-speed differential pair flat cable with modular twisted-pair data connector," which in turn claims the benefit and priority of U.S. Provisional Application No. 63 / 687,215, filed April 11, 2025, entitled "High-speed differential pair flat cable with modular twisted-pair data connector," the contents of which are incorporated herein by reference. Technical Field

[0003] This article discloses a topic related to flat high-speed data cables, and more particularly to a high-speed differential pair flat cable with a modular twisted-pair data connector. Background Technology

[0004] The use of flat cables in high-speed data transmission applications has been limited by various technical challenges. One major problem is the difficulty in constructing shielded flat data cables that are both robust and have low insertion loss characteristics. Existing flat cables are typically thin and do not support high-speed data capabilities due to high signal loss and electromagnetic compatibility (EMC) issues. Therefore, attaching terminals to flat cables has been a significant challenge. Crimping terminals onto flat cables has been employed, but it provides insufficient radio frequency (RF) performance for data transmission. Soldering terminals to flat cables has also been attempted, but this leads to degradation and melting of the flat cable's dielectric material.

[0005] Previous approaches focused on developing new interface systems and components to address the limitations of flat cables. For example, some manufacturers have developed round wire components for high-frequency applications. However, these components are typically bulky and expensive, making them less than ideal for use in flat cable assemblies. Other attempts have attempted to develop new flat cables with improved shielding and signal integrity, but these cables are often difficult to manufacture and assemble. Furthermore, the use of modular connectors has been explored, but these connectors typically require complex and expensive assembly processes.

[0006] These issues are largely well-known in the industry. For these reasons, some original equipment manufacturers (OEMs) avoid using flat cables in applications. Previous approaches have attempted to address the challenges of flat cable assemblies through various means, but none of these approaches have provided a comprehensive solution that incorporates the features described in this disclosure. Summary of the Invention

[0007] According to one aspect, the technology described herein relates to a differential pair flat cable, including a planar substrate, at least one signal conductor disposed within the planar substrate, a shielding conductor disposed on one or more surfaces of the planar substrate, at least one exposed signal connection pad connected to the signal conductor, and at least one groove defined in an end portion of the planar substrate and an exposed portion of the shielding conductor. The groove defines opposing lateral wall surfaces configured to mechanically constrain lateral movement of a vertical shielding tab received within the groove. The exposed portion of the shielding conductor adjacent to the groove is configured to be directly attached to the vertical shielding tab to provide mechanical retention and electrical grounding.

[0008] According to another aspect, the technology described herein relates to a differential pair flat cable assembly, including a flat cable having a planar substrate and a longitudinal axis. The flat cable includes a differential pair of signal conductors disposed within the planar substrate, signal connection pads exposed at the ends of the flat cable, shielding conductors disposed on an outer surface of the planar substrate, and at least one groove extending from a first surface through the planar substrate and the shielding conductors to an opposing second surface. The cable assembly further includes a connector assembly mounted to the ends of the flat cable. The connector assembly includes an inner signal terminal having a mating contact portion and an attachment tail portion. The attachment tail portion is directly mechanically and electrically attached to the exposed signal connection pads of the differential pair. The connector assembly also includes a conductive inner shielding terminal surrounding the inner signal terminal, including at least one integral vertical tab extending axially from the inner shielding terminal toward the flat cable. The vertical tab is received within the groove of the flat cable such that opposing lateral surfaces of the groove constrain lateral movement of the inner shielding terminal relative to the flat cable, and an electrically insulating inner housing is radially disposed between the inner signal terminal and the inner shielding terminal. The connector assembly further includes an outer shielding terminal that is mechanically and electrically connected to the inner shielding terminal before being engaged with the flat cable to form a rigid shielding terminal assembly. Attached Figure Description

[0009] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings, wherein: Figure 1 An exploded perspective view of a differential flat cable assembly according to some embodiments is shown.

[0010] Figure 2A The settings according to some embodiments are shown. Figure 1 A top view of the differential pairs of the signal conductors within the differential pair flat cable assembly.

[0011] Figure 2B Illustrations based on some embodiments Figure 2AA bottom view of the shielded conductor of a flat cable with differential polarity.

[0012] Figure 2C Illustrations based on some embodiments Figure 2A A top view of the shielded conductor of a differential pair flat cable.

[0013] Figure 2D Illustrations based on some embodiments Figure 2A A top view of the insulating overlay on the shielding conductor of a differential flat cable.

[0014] Figure 3A The attachment according to some embodiments is shown. Figure 2A A top view of the signal connection pads of the differential pair flat cable's signal conductors and the inner signal terminals.

[0015] Figure 3B The attachment according to some embodiments is shown. Figure 3A Side view of the inner signal terminal of the signal connection pad.

[0016] Figure 4 Illustrations based on some embodiments Figure 1 A three-dimensional view of the connector assembly of the differential pair flat cable assembly.

[0017] Figure 5A and Figure 5B An assembly sequence is shown for attaching an internal signal terminal to a signal connection pad of a differential pair of signal conductors, according to some embodiments.

[0018] Figure 6A and Figure 6B The assembly of an outer shielding terminal, an insulating inner housing, and an inner shielding terminal according to some embodiments is shown to form Figure 4 The assembly sequence of the connector components.

[0019] Figure 7 The following are examples of embodiments: Figure 4 The connector assembly is a step in the assembly sequence.

[0020] Figure 8 The following are examples of embodiments: Figure 4 The connector assembly is another step in the assembly sequence.

[0021] Figure 9 The following are examples of embodiments: Figure 4 This is another step in the assembly sequence of the connector components.

[0022] Figure 10A and Figure 10B Perspective top and bottom views are shown of the connection point from the inner shield terminal of the connector assembly to the shield conductor of the flat cable according to some embodiments.

[0023] Figure 11A Illustrations based on some embodiments Figure 1 A side view of a differential pair flat cable assembly, wherein the connector assembly is inserted into an insulating housing.

[0024] Figure 11B Illustrations based on some embodiments Figure 11A A three-dimensional top view of the connector assembly.

[0025] Figure 12 Computer simulation based on some embodiments is shown. Figure 1 The return loss diagram of the differential pair flat cable assembly.

[0026] Figure 13 This illustrates measurements based on actual samples according to some embodiments. Figure 1 The return loss diagram of the differential pair flat cable assembly. Detailed Implementation

[0027] The problem of attaching high-speed shielded flat cables using industry-standard high-speed terminal connector interfaces has been solved by introducing a robust, low-loss flat cable. This flat cable features sliding modular twisted-pair data type connector terminals that are compatible with H-MTD type mating connectors or connectors of similar geometry used in automotive networking applications, and is capable of supporting frequencies up to 20 GHz and data transmission rates up to 56 Gbit / sec. H-MTD® is a registered trademark of Rosenberger Hochfrequenztechnik GmbH & Co.

[0028] The following description is provided to enable those skilled in the art to make and use the invention. Various modifications to the embodiments described herein will be apparent to those skilled in the art.

[0029] The embodiments described herein generally relate to high-speed flat data cables and connector assemblies, and more specifically to a differential pair flat cable configured for connection to a modular twisted-pair data connector interface. The disclosed structure enables a reliable electrical connection between the flat printed circuit cable and the high-speed connector terminals, while maintaining good mechanical retention and signal integrity characteristics.

[0030] First see Figure 1The diagram illustrates a differential pair flat cable assembly, hereinafter referred to as cable assembly 100. The cable assembly 100 includes a flat cable 102 and a connector assembly 104 attached to an end portion of the flat cable 102. The connector assembly 104 is configured to provide both electrical and mechanical interfaces between the flat cable 102 and a corresponding mating connector of another electrical cable or electronic device (not shown).

[0031] In some embodiments, connector assembly 104 may conform to the H-MTD® modular twisted-pair data connector interface, which is commonly used in automotive networking applications that can support high-frequency data transmission.

[0032] The flat cable 102 may include a flexible printed circuit (FPC) structure comprising multiple conductive and dielectric layers configured to support high-speed differential signal transmission.

[0033] Connector assembly 104 may include inner signal terminals 106, each having a mating contact portion 108 and an attachment tail portion 110. The attachment tail portion 110 is configured to be directly mechanically and electrically attached to the flat cable 102. Connector assembly 104 may also include conductive inner shielding terminals 112 configured to surround the inner signal terminals 106. The inner shielding terminal 112 includes at least one integral vertical shielding tab 114, in the illustrated example two shielding tabs 114, extending axially from the inner shielding terminal 112 toward the flat cable 102. The vertical shielding tab 114 is received within a slot 116 in the flat cable 102 such that opposing lateral surfaces of the slot 116 constrain lateral movement of the inner shielding terminal 112 relative to the flat cable 102. Connector assembly 104 may further include an electrically insulating inner housing 118 radially disposed between the inner signal terminals 106 and the inner shielding terminals 112. The connector assembly 104 may further include an outer shielding terminal 120 that is mechanically and electrically connected to an inner shielding terminal 112 to form a rigid shielding terminal assembly before engagement with the flat cable 102. The outer shielding terminal 120 provides a mating interface with a corresponding mating connector, while the inner shielding terminal 112 connects the outer shielding terminal 120 to the shielding conductor 210.

[0034] See Figure 2AThe diagram shows a top view of a flat cable 102. Signal conductors 202 may be copper traces arranged to form differential pair transmission lines extending longitudinally along the flat cable 102. These signal conductors 202 terminate at exposed signal connection pads 206 located at the end portions of the flat cable 102. These pads 206 are configured to receive attachment tail portions 110 of inner signal terminals 106. A gap 208 may be defined in a planar substrate located between the first and second signal connection pads. This gap 208 may be configured to receive a portion of an inner housing 118 or an inner shield terminal 112 to maintain symmetrical positioning of the inner signal terminal 106 relative to the inner shield terminal 112.

[0035] In some embodiments, the signal conductor 202 includes periodically crossed regions with an insulating layer of substrate 204 between these regions, thereby forming a periodically crossed differential pair configuration that simulates twisted-pair electromagnetic coupling along the cable length to reduce electromagnetic interference and maintain balanced impedance characteristics.

[0036] See Figure 2B The flat cable 102 includes a signal conductor 202 disposed on or within a planar substrate 204. A shielding conductor 210 is positioned along the surface of the substrate 204. The shielding conductor 210 may be formed as a continuous metal layer, such as copper, and may serve as electromagnetic shielding for the signal conductor 202.

[0037] Back Figure 2A The flat cable 102 may include a transition region between a pad 206 and a signal conductor 202. In some embodiments, the ratio of the pad length to the transition region length may be approximately 3:4 ±5%, and the ratio of the conductor width to the conductor spacing may remain substantially constant throughout the transition region. These geometric relationships help maintain the target differential impedance. Figure 2B The shielding conductor on the bottom surface shown overlaps with the transition region to provide the target differential impedance through the transition region.

[0038] See Figure 2C The diagram shows a top view of a flat cable 102, illustrating the exposed portion of the shielding conductor 210 near the cable end. These exposed portions can provide an electrical attachment surface for the inner shielding terminal 112. Figure 2B The shielding conductor 210 on the bottom surface of the substrate 204 is electrically connected via a conductive surface on the edge of the substrate 204 and / or via one or more conductive vias through the substrate 204. Figure 2C Shielding conductor 210 on the top surface of the middle substrate 204.

[0039] See Figure 2DThe flat cable 102 may further include an insulating overlay or cover layer 212 disposed over a portion of the shielding conductor 210. The cover layer 212 may include openings that expose selected conductive areas, such as pad 206 and shielding attachment area 214.

[0040] The flat cable 102 may include a laminated structure comprising a signal layer, a dielectric layer, and a shielding layer, arranged to provide controlled impedance transmission characteristics. In an exemplary embodiment, the flat cable may include an acrylic copper-clad laminate, such as PYRALUX® LF, a polyamide double-sided copper-clad laminate, such as PYRALUX® AP, and / or a high-performance epoxy adhesive, such as PYRALUX® HP. PYRALUX® is a trademark of Qnity Electronics, Inc.

[0041] See Figure 3A Internal signal terminals 106 are positioned onto pads 206 of a flat cable. Each internal signal terminal 106 includes: an attachment tail portion 110 configured for electrical and mechanical attachment to pad 206; and a mating contact portion 108 configured for engaging a mating connector. In some embodiments, pad 206 includes an exposed copper area to facilitate reliable attachment of the internal signal terminals 106. Without exhaustive listing, the attachment tail portion 110 may be attached to pad 206 using soldering, fusion welding, or conductive adhesive.

[0042] See Figure 3B The image shows a side view of the inner signal terminal attached to the pad. The attachment tail portion 110 of the inner signal terminal 106 is attached to the pad 206 to establish an electrical connection with the signal conductor 202 of the flat cable 102.

[0043] In some embodiments, such as Figure 3B As shown, each internal signal terminal may include a stop surface 302 located between the attachment tail portion 110 and the mating contact portion 108. The stop surface 302 may engage the edge 304 of the substrate 204 to establish proper axial positioning of the terminal 106 relative to the flat cable 102.

[0044] See Figure 4 The diagram illustrates a connector shielding terminal assembly 402. This shielding terminal assembly may include an outer shielding terminal 120, an inner housing 118, and an inner shielding terminal 112. The inner housing 118 may be positioned within the outer shielding terminal 120, and the inner shielding terminal 112 may be attached to the outer shielding terminal 120 to form a rigid shielding terminal assembly 402. This connector shielding terminal assembly 402 may be manufactured separately before being installed onto the flat cable 102.

[0045] See Figure 5A and Figure 5B The diagram illustrates the assembly sequence for attaching the internal signal terminal 106 to the flat cable 102.

[0046] exist Figure 5A In the middle, the internal signal terminal 106 is positioned on the exposed pad 206. Figure 5B In this configuration, the internal signal terminal 106 is attached to the pad 206 to form an electrical connection between the internal signal terminal 106 and the signal conductor 202. In some embodiments, solder paste may be applied to the pad 206 prior to placement of the terminal to facilitate the soldering process.

[0047] See Figure 6A and Figure 6B The connector shielding terminal assembly 402 is mounted on the inner signal terminal 106.

[0048] The inner shielding terminal 112 includes vertical shielding tabs 114 extending axially toward the flat cable 102. These shielding tabs 114 are configured to be received within slots 116 defined in the flat cable 102. Each slot 116 has an open end 502 and a closed end 504. The open end 502 is chamfered, for example at a 45° angle from the outer edge of the substrate to the outer wall of the slot 116, to guide the shielding tabs 114 into the slot 116.

[0049] The slot 116 extends through the substrate 204 and shielding conductor 210 of the flat cable 102. The walls of the slot 116 may have conductive surfaces and may electrically and mechanically connect the shielding conductor 210 on the top surface of the substrate 204 to the shielding conductor 210 on the bottom surface of the substrate 204. These walls may be plated with a conductive material, including a conductive layer wrapped over the shielding conductor 210, or may define a plurality of conductive vias between the shielding conductor 210 on the top and bottom surfaces of the substrate 204. When the shielding tab 114 is inserted into the slot 116, the lateral surfaces of the slot 116 constrain the lateral movement of the connector assembly 104 relative to the flat cable 102. The substrate 204 is semi-rigid and has bending stiffness sufficient to withstand longitudinal forces in the range of 20 to 40 Newtons without bending in a lateral direction perpendicular to the direction in which the longitudinal force is applied. This allows the substrate 204 to push the inner signal terminal 106 into the inner housing 118 without bending.

[0050] See Figures 7 to 9 During installation, connector assembly 104 advances toward the cable end. Vertical shielding tab 114 enters slot 116 and guides connector assembly 104 to the correct alignment position.

[0051] Once fully inserted, the shielding tab 114 is mechanically and electrically attached to the exposed portion of the shielding conductor 210, thereby providing electrical grounding and mechanical holding force to the connector assembly 104 to the flat cable 102. This arrangement provides a robust attachment between the connector assembly and the flat cable.

[0052] See Figure 10A and Figure 10B The diagram illustrates the connection interface between the connector assembly and the flat cable in more detail. In some embodiments, the rear tab 1002 of the inner shield terminal 112 may also be engaged and attached to the shield conductor 210, for example by soldering or welding.

[0053] A vertical shielding tab 114 extends into a groove 116 and attaches to the shielding conductor 210, for example, by using a solder joint, laser welding, resistance welding, conductive adhesive, or mechanical crimping. This configuration establishes a low-impedance electrical path between the shielding conductor 210 and the inner shielding terminal 112, thereby improving electromagnetic compatibility.

[0054] See Figure 11A and Figure 11B The connector assembly can be positioned within an insulating housing 1102. This housing may include a locking feature 1104 configured to engage a corresponding mating connector (not shown). Figure 11A As shown, locking features 1104 of each housing 1102 are arranged on opposite sides of assembly 100. This allows the internal signal terminals to have the correct orientation with their corresponding mating connectors. Figure 11B As shown, in some embodiments, the connector housing may include a stress relief region 1106 in which an adhesive or epoxy material is applied between the housing 1102 and the flat cable 102 to reinforce the cable-to-connector interface.

[0055] Figure 12 The simulated return loss diagram of the cable assembly is shown, and Figure 13 Several sample return loss graphs for this cable assembly are shown. These graphs illustrate the electrical performance of the differential pair connection system over a certain frequency range.

[0056] The cable assembly 100 can be manufactured using modified terminal components derived from existing round wire connector designs. In some embodiments, the inner signal terminal 106 can be modified to include a flat attachment surface compatible with the pad 206, and the inner shield terminal 112 can be modified to accommodate flat cable access. In high-volume production, these inner signal terminals 106 can be manufactured using stamped and formed copper alloy components supplied via reel for automated assembly.

[0057] Assembly processes may include: Place the internal signal terminal 106 on the pad 206; Attach the internal signal terminal 106 to the pad 206; The inner shielding terminal 112 is mounted on the inner signal terminal 106, wherein the inner shielding terminal 112 provides a clearance for sliding on the inner signal terminal 106; Insert the shielding protrusion 114 into the slot 116; Attach the shielding tab 114 to the shielding conductor 210; and Install the outer casing 1102.

[0058] The disclosed cable assembly 100 is particularly useful in high-speed automotive communication systems, including cameras and imaging systems, radar and lidar sensors, advanced driver assistance systems (ADAS), and vehicle network architectures. Compared to conventional round twisted-pair cables, the disclosed flat cable structure allows for smaller package size, improved wiring flexibility, and easier integration into compact electronic modules.

[0059] Although specific embodiments have been described, various modifications may be made without departing from the scope of the invention.

[0060] For example: The number and position of the shielding tabs and slots can be varied.

[0061] Alternative connector interface standards can be used. A single signal conductor can be used, and / or Additional signal conductor pairs can be incorporated into the cable assembly.

[0062] While the invention has been described with reference to exemplary embodiments (multiple), those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from the scope of the invention. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from its basic scope. Therefore, it is intended that the invention be limited to the disclosed embodiments (multiple), but rather that the invention encompass all embodiments falling within the scope of the appended claims.

[0063] As used herein, “one or more” includes functions performed by a single element, functions performed by more than one element, such as elements in a distributed manner, multiple functions performed by a single element, multiple functions performed by multiple elements, or any combination of the foregoing.

[0064] It should also be understood that although the terms first, second, etc., are sometimes used herein to describe various elements, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, without departing from the scope of the various embodiments described, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact. Both the first contact and the second contact are contacts, but they are not the same contact.

[0065] The terminology used herein to describe various embodiments is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the descriptions of the various embodiments and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and covers any and all possible combinations of one or more of the associated listed items. It should also be further understood that the terms “includes,” “including,” “comprises,” and / or “comprising,” when used in this specification, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0066] As used herein, the term "if" may be interpreted selectively, depending on the context, as meaning "when," "at," "in response to determination," or "in response to detection." Similarly, the phrase "if determination" or "if [the condition or event of the statement] is detected" may be interpreted selectively, depending on the context, as meaning "when determination," "in response to determination," "when [the condition or event of the statement] is detected," or "in response to the detection of [the condition or event of the statement]."

[0067] Furthermore, although terms indicating order or direction may be used herein, these elements should not be limited by such terms. All terms indicating order or direction, unless otherwise stated, are for the purpose of distinguishing one element from another and, unless otherwise stated, do not indicate any particular order, sequence of operations, direction, or orientation.

[0068] Discussion of possible embodiments

[0069] The following is a non-exclusive description of possible embodiments of the present invention.

[0070] According to one aspect, the technology described herein relates to a differential pair flat cable, including a planar substrate, at least one signal conductor disposed within the planar substrate, a shielding conductor disposed on one or more surfaces of the planar substrate, at least one exposed signal connection pad connected to the signal conductor, and at least one groove defined in an end portion of the planar substrate and an exposed portion of the shielding conductor. The groove defines opposing lateral wall surfaces configured to mechanically constrain lateral movement of a vertical shielding tab received within the groove. The exposed portion of the shielding conductor adjacent to the groove is configured to be directly attached to the vertical shielding tab to provide mechanical retention and electrical grounding.

[0071] The cables described in the preceding paragraphs may optionally, additionally and / or alternatively include any one or more of the following features / steps, configurations and / or additional components.

[0072] For example, the end portion of the planar substrate adjacent to the groove can be chamfered to facilitate the insertion of the vertical shielding tab into the groove and to align the shielding tab with respect to the planar substrate.

[0073] For example, the end portion of the planar substrate adjacent to the groove can be chamfered from the outer edge of the planar substrate toward the groove.

[0074] For example, the at least one signal conductor may include a first signal conductor and a second signal conductor, the second signal conductor being arranged together with the first signal conductor in a differential pair configuration, wherein the at least one exposed signal connection pad includes a first signal connection pad and a second signal connection pad, and wherein the second signal connection pad is arranged parallel to the first signal connection pad.

[0075] For example, the first and second signal conductors may have multiple intersections, thereby providing a pair of twisted signal conductors along the planar substrate.

[0076] For example, the at least one slot may include a first slot and a second slot arranged parallel to the first slot. The first and second slots may be configured to receive corresponding vertical shielding tabs of the inner shielding terminal, such that the opposing lateral walls of the first and second slots constrain the lateral movement of the inner shielding terminal relative to the planar substrate.

[0077] For example, the planar substrate includes a portion of a signal connection pad that can extend axially beyond the slot. This portion can be configured such that the stop surface of the inner signal terminal engages the edge of the planar substrate to establish axial positioning of the inner shield terminal relative to the flat cable.

[0078] For example, the gap can be defined within the planar substrate, located between the first and second signal connection pads. This gap can be configured as part of a receiver connector housing or shielding structure to maintain the symmetrical positioning of the differential pair relative to the connector.

[0079] For example, the cable may further include a first transition region and a second transition region, connecting the first signal connection pad to the first signal conductor and the second signal connection pad to the second signal conductor, respectively. The ratio of the terminal pad length to the transition region length may be 3:4 ± 5% to maintain the target differential impedance throughout the transition region.

[0080] For example, the transition between the signal connection pad and the signal conductor may include a tapered trace geometry configured to maintain differential impedance.

[0081] For example, the ratio of conductor width to gap width remains substantially constant along the length of the transition zone to reduce impedance discontinuities between the signal connection pad and the main transmission section of the flat cable.

[0082] For example, the internal signal terminal may be a modified round wire terminal with an attachment surface configured to attach to a signal pad on a flat cable.

[0083] For example, the signal connection pad may include an exposed copper area configured to receive solder paste for attaching the internal signal terminal.

[0084] For example, the flat cable may include isolation grooves located between the signal connection pads to electrically isolate the differential pair terminals.

[0085] For example, the connector assembly may further include a stress-relief region filled between the connector housing and the flat cable with an adhesive or epoxy resin material.

[0086] For example, the outer shield terminal includes a modified rear portion to accommodate the flat cable within the terminal assembly.

[0087] For example, the vertical shielding tab can extend through the slot until the stop surface of the connector assembly engages the cable end.

[0088] For example, the groove can extend through both the planar substrate and the shielding conductor of the flat cable.

[0089] For example, the dimensions of the slot can be designed to constrain the lateral movement of the shield terminal relative to the cable during connector assembly.

[0090] According to another aspect, the technology described herein relates to a differential pair flat cable assembly, including a flat cable having a planar substrate and a longitudinal axis. The flat cable includes a differential pair of signal conductors disposed within the planar substrate, signal connection pads exposed at the ends of the flat cable, shielding conductors disposed on an outer surface of the planar substrate, and at least one groove extending from a first surface through the planar substrate and the shielding conductor to an opposing second surface. The cable assembly further includes a connector assembly mounted to the ends of the flat cable. The connector assembly includes an inner signal terminal having a mating contact portion and an attachment tail portion. The attachment tail portion is directly mechanically and electrically attached to the exposed signal connection pads of the differential pair. The connector assembly also includes a conductive inner shielding terminal surrounding the inner signal terminal, including at least one integral vertical tab extending axially from the inner shielding terminal toward the flat cable. The vertical tab is received within the groove of the flat cable such that opposing lateral surfaces of the groove constrain lateral movement of the inner shielding terminal relative to the flat cable, and an electrically insulating inner housing is radially disposed between the inner signal terminal and the inner shielding terminal. The connector assembly further includes an outer shielding terminal that is mechanically and electrically connected to the inner shielding terminal before being engaged with the flat cable to form a rigid shielding terminal assembly.

[0091] The cable assembly described in the preceding paragraph may optionally, additionally and / or alternatively include any one or more of the following features / steps, configurations and / or additional components.

[0092] For example, the vertical tab can be mechanically and electrically attached directly to the shielding conductor on the flat cable.

[0093] For example, the connector assembly can be secured to the flat cable via conductive joints at the signal connection pad and the shielding conductor.

[0094] For example, the bending stiffness of the planar substrate can be sufficient to suppress deformation of the planar substrate when the inner signal terminal and the inner shield terminal are pushed into the connector housing.

[0095] For example, the bending stiffness can be sufficient to withstand longitudinal forces in the range of 20 to 40 Newtons without bending in the lateral direction perpendicular to the direction in which the longitudinal force is applied.

[0096] For example, the connector assembly may include an insulating housing in which the shielded terminal assembly is positioned. The housing may include a locking feature configured to secure the connector assembly to a corresponding mating connector assembly.

[0097] For example, the cable assembly may include two connector assemblies, each positioned at one end of the flat cable. The locking feature of one connector assembly located at one of the two ends may be arranged on the opposite side of the housing relative to the locking feature of the other connector assembly located at the other end.

[0098] For example, the locking feature may include a shark fin-shaped protrusion configured to be received within an orifice defined by the corresponding mating connector assembly.

[0099] For example, the internal signal terminal may define a stop surface between the mating contact portion and the attachment tail portion. The stop surface may contact the end of the planar substrate.

[0100] For example, the signal connection pad may be recessed relative to the outer surface of the planar substrate, so that the axial centerline of the inner signal terminal coincides with the axial centerline of the planar substrate.

[0101] According to another aspect, the technology described herein relates to a method for assembling a differential pair flat cable assembly, comprising the steps of: positioning an inner signal terminal on an exposed signal pad of the flat cable, attaching the inner signal terminal to the signal pad, inserting a shielding terminal assembly onto the inner signal terminal, inserting at least one shielding tab of the shielding terminal assembly into a slot of the flat cable, and attaching the shielding tab to an exposed portion of the shielding conductor of the flat cable.

[0102] The methods described in the preceding paragraphs may optionally, additionally and / or alternatively include any one or more of the following features / steps, configurations and / or additional components.

[0103] For example, the method may further include mounting an external connector housing on top of the shielded terminal assembly.

[0104] For example, solder paste can be applied to the signal pad before positioning the internal signal terminal.

[0105] According to another aspect, the technology described herein relates to a differential pair flat cable, including a flexible dielectric substrate, a pair of signal conductors forming a differential transmission line, a shielding conductor disposed on at least one surface of the substrate, an exposed terminal pad connected to the signal conductors, and at least one slot of a shielding tab configured to receive a connector assembly.

Claims

1. A differential pair flat cable (102), comprising: Planar substrate (204); At least one signal conductor (202) is disposed within the planar substrate (204); A shielding conductor (210) is disposed on one or more surfaces of the planar substrate (204); At least one exposed signal connection pad (206) is connected to the signal conductor (202); as well as At least one slot (116) is defined in an end portion of the planar substrate (204) and an exposed portion of the shielding conductor (210), the slot (116) defining opposing lateral wall surfaces configured to mechanically constrain lateral movement of a vertical shielding tab (114) receiving a conductive inner shielding terminal (112) within the slot (116), the exposed portion of the shielding conductor (210) adjacent to the slot (116) being configured to be directly attached to the vertical shielding tab (114) to provide mechanical retention and electrical grounding.

2. The cable (102) according to claim 1, characterized in that, The end portion of the planar substrate (204) adjacent to the groove (116) is chamfered to facilitate the insertion of the vertical shielding tab (114) into the groove (116) and to align the shielding tab (114) with respect to the planar substrate (204).

3. The cable (102) according to claim 2, characterized in that, The end portion of the planar substrate (204) adjacent to the groove (116) is chamfered from the outer edge (304) of the planar substrate (204) toward the groove (116).

4. The cable (102) according to claim 1, characterized in that, The at least one signal conductor (202) includes a first signal conductor (202) and a second signal conductor (202) arranged in a differential pair configuration with the first signal conductor (202), wherein the at least one exposed signal connection pad (206) includes a first signal connection pad (206) and a second signal connection pad (206), and wherein the second signal connection pad (206) is arranged parallel to the first signal connection pad (206).

5. The cable (102) according to claim 4, characterized in that, The first signal conductor and the second signal conductor (202) have multiple intersection points, thereby providing a pair of twisted signal conductors (202) along the planar substrate (204).

6. The cable (102) according to claim 4, characterized in that, The at least one slot (116) includes a first slot (116) and a second slot (116) arranged parallel to the first slot (116), wherein the first slot and the second slot (116) are configured to receive corresponding vertical shielding tabs (114) of the inner shielding terminal (112), such that the opposing lateral walls of the first slot and the second slot (116) constrain the lateral movement of the inner shielding terminal (112) relative to the planar substrate (204).

7. The cable (102) according to claim 6, characterized in that, A portion of the planar substrate (204) including the signal connection pad (206) extends axially beyond the groove (116), the portion being configured such that the stop surface (302) of the inner signal terminal (106) engages the edge (304) of the planar substrate (204) to establish axial positioning of the inner shield terminal (112) relative to the flat cable (102).

8. The cable (102) according to claim 7, characterized in that, A gap (208) is defined in the planar substrate (204) between the first signal connection pad and the second signal connection pad (206), the gap (208) being configured to receive a portion of the connector housing (1102) or shielding structure (402) to maintain the symmetrical positioning of the differential pair (202) relative to the connector.

9. The cable (102) according to claim 4, characterized in that, The cable (102) further includes a first transition region and a second transition region respectively connecting the first signal connection pad (206) to the first signal conductor (202) and connecting the second signal connection pad (206) to the second signal conductor (202), wherein the ratio of the length of the terminal pad to the length of the transition region is 3:4 ± 5% to maintain the target differential impedance throughout the transition region.

10. The cable (102) according to claim 9, characterized in that, The ratio of conductor width to conductor gap width remains substantially constant along the length of the transition zone to reduce impedance discontinuities between the signal connection pad (206) and the main transmission portion of the flat cable (102).

11. A differential pair flat cable assembly (100), comprising: A flat cable (102) having a planar substrate (204) and a longitudinal axis, the flat cable (102) comprising: Differential pairs (202) of signal conductors are disposed within the planar substrate (204). A signal connection pad (206) is exposed at the end of the flat cable (102). A shielding conductor (210) is disposed on the outer surface of the planar substrate (204), and At least one groove (116) extending from a first surface through the planar substrate (204) and the shielding conductor (210) to an opposing second surface; and A connector assembly (104) is mounted to the end of the flat cable (102), the connector assembly (104) comprising: An internal signal terminal (106) has a mating contact portion (108) and an attachment tail portion (110) which is directly mechanically and electrically attached to the exposed signal connection pad (206) of the differential pair. A conductive inner shielding terminal (112) surrounds the inner signal terminal (106) and includes at least one integral vertical tab (114) extending axially from the inner shielding terminal (112) toward the flat cable (102). The vertical tab (114) is received within a groove (116) of the flat cable (102) such that opposing lateral surfaces of the groove (116) constrain lateral movement of the inner shielding terminal (112) relative to the flat cable (102). An electrically insulating inner housing (118) is radially disposed between the inner signal terminal (106) and the inner shielding terminal (112), and An outer shielding terminal (120) is mechanically and electrically connected to the inner shielding terminal (112) before being coupled to the flat cable (102) to form a rigid shielding terminal assembly (402).

12. The cable assembly (100) according to claim 11, characterized in that, The vertical tab (114) is mechanically and electrically attached directly to the shielding conductor (210) on the flat cable (102).

13. The cable assembly (100) according to claim 11, characterized in that, The connector assembly (104) is secured to the flat cable (102) via conductive joints at the signal connection pad (206) and the shielding conductor (210).

14. The cable assembly (100) according to claim 11, characterized in that, The bending stiffness of the planar substrate (204) is sufficient to suppress deformation of the planar substrate (204) when the inner signal terminal (106) and the inner shield terminal (112) are pushed into the connector housing.

15. The cable assembly (100) according to claim 14, characterized in that, The bending stiffness is sufficient to withstand longitudinal forces in the range of 20 to 40 Newtons without bending in a lateral direction perpendicular to the direction in which the longitudinal force is applied.

16. The cable assembly (100) according to claim 11, characterized in that, The connector assembly (104) includes an insulating housing (1102), the shielded terminal assembly is located within the housing (1102), and the housing (1102) includes a locking feature configured to secure the connector assembly (104) to a corresponding mating connector assembly (104).

17. The cable assembly (100) according to claim 16, characterized in that, The cable assembly (100) includes two connector assemblies (104), which are respectively placed on each end of the two ends of the flat cable (102), and wherein the locking feature (1104) of one connector assembly (104) located on one of the two ends is arranged on the opposite side of the housing (1102) relative to the locking feature (1104) of the other connector assembly (104) located on the other end of the two ends.

18. The cable assembly (100) according to claim 16, characterized in that, The locking feature (1104) includes a shark fin-shaped protrusion configured to be received within an aperture defined by the corresponding mating connector assembly.

19. The cable assembly (100) according to claim 17, characterized in that, The internal signal terminal (106) defines a stop surface (302) between the mating contact portion (108) and the attachment tail portion (110), and wherein the stop surface (302) contacts the end of the planar substrate (204).

20. The cable assembly (100) according to claim 19, characterized in that, The signal connection pad (206) is recessed relative to the outer surface of the planar substrate (204), so that the axial center line of the inner signal terminal coincides with the axial center line of the planar substrate (204).

Images