Bipolar conductor connector system

Abstract

A bipolar conductor connector system (1) for a single pair Ethernet application comprises a stationary connector (100) having a housing (101) and an electrical contact element (102) and a plug connector (105) having an electrical contact (104) configured for attachment to a single pair of cables. The bipolar conductor connector system (1) further comprises a key device (103) configured for unambiguously inserting the plug connector (105) into the stationary connector (100) in a predetermined direction.

Description

TECHNICAL FIELD

[0001] The present solution relates to a dual conductor connector system for electrical and mechanical connection of electrical conductors for electrical and electronic equipment, including shielded and unshielded free and fixed connectors and plug-in connectors, in particular for single-pair Ethernet, but not limited thereto. BACKGROUND

[0002] Single-pair Ethernet (SPE) is gaining attention for automotive applications for industrial and building automation, as well as other applications. It is considered to represent the next generation of communication architecture in, for example, smart factories and Industrial Internet of Things (IIoT). SPE technology delivers high performance data and power transfer over a single twisted pair instead of two or four twisted pairs. Many applications can be more cost effective due to the lower cost of SPE, thus more attractive. Using SPE has the added advantage of being able to merge with other Ethernet protocols in use, allowing for expansion while avoiding the need to rip and replace existing communications or add complexity of gateways. In addition, not only is cost reduced by installing less material, but existing systems are more easily expanded compared to eight-wire cables. With thinner and lighter cables, more Ethernet channels can be accommodated in existing cable runs than before to improve the construction and size for new applications. Alternatively, a bundle of 1-pair cables to 4-pair cables can be used to efficiently transport up to 4 independent applications and split them at each end, also known as cable sharing.

[0003] Another particularly important feature of SPE is the possibility of supplying power to connected peripheral devices through PoDL (Power over Data Line) in parallel with data transfer. This allows any device to be connected with only one cable, thus providing data and power on the same interface. Adding PoDL is an additional reason for using copper cable to reduce cost. If the power requirements exceed the specification, power can be run separately. But in most cases, there is no need to increase the amount of copper running on separate power cables for sensors and actuators.

[0004] The basis of SPE is the development of international standards for the technology. The physical properties and transmission rates are defined internationally by different standardization bodies. Data transmission rates of 10 Mbit / s up to 1000 m and 1 Gbit / s up to 40 m to 100 m are sufficient. In today's PoE applications, power delivery to the end device at the four-pair power sourcing equipment (PSE) requires up to 90 W. With PoDL technology, the highest power level currently to be delivered to the powered device (PD) is 50 W, with a maximum current of 1.579 A.

[0005] Furthermore, PoDL opens up further applications for SPE, for example the construction of infrastructure and / or production under extreme conditions, with the advantage that the infrastructure is easy to install due to the miniaturized connectors and single-pair cables. SPE shows further advantages, for example thinner bend radius, smaller cables and transmission rates of up to 1 Gbit / s or more on a single pair.

[0006] It is known from EP2649686 a multi-pole outlet for a conductor connector system having cable sharing capabilities described in several European and international cable standards suitable for frequencies up to 4000 MHz. The outlet comprises a housing which is divided into at least two chambers, said at least two chambers being separated from each other by a separating element. Each chamber has two contacts which are accessible from a first end of the chamber, wherein the contacts pass through an insert parallel to a longitudinal axis of the housing. Separators for separating the wires and for holding the wires in place are arranged to form an end piece for the chamber at a second end opposite the first end, wherein the contacts are arranged to be electrically connected to the wires when the separators are in place in the housing. Utility model content

[0007] The general requirements for connectors for single-pair Ethernet defined in the parent standard are such that the general electrical requirements for different interfaces are the same for all connectors of a particular series standard. The mechanical mating information, pin assignment and additional requirements for each connector are standardized in the detailed specification. These vary in mating face, nomenclature and interface, size and mechanical performance. It is therefore an object of the present solution to provide a dual-pole conductor connector system for single-pair Ethernet applications that complies with current and upcoming application standards provided by the Institute of Electrical and Electronics Engineers (IEEE) and other organizations. In particular, the dual-pole conductor connector system is configured for electrical and electronic equipment including shielded and unshielded free and fixed connectors with up to 8 lines. The dual-pole conductor connector provides mechanical mating information described as a keying function.

[0008] It is another object of the present solution to provide a conductor connector system including plugs and jacks and sockets that can be combined into a 2-pair interface or a 4-pair interface or other number of pairs.

[0009] It is another object of the present solution to provide a conductor connector system designed to allow high currents up to 4A and above, combined with the requirements below the Low Voltage Directive (LVD) limits. The LVD requirements cover the health and safety risks of electrical equipment operating at input or output voltages between 50 and 1000 V AC or between 75 and 1500 V DC. Therefore, the LVD prescribes electrical characteristics for electrical equipment, such as cables, power supply units, etc., for consumer and professional use. The power transfer through the connector and cable is generated to keep always below these voltages.

[0010] The unique combination of low to high data transfer rates and low to high power transfer rates provided by the bipolar conductor connector system of the present solution, and any combination thereof, makes the system useful in many areas of home, office, industrial and distributed building services.

[0011] According to the present solution, the bipolar conductor connector system comprises a connector having a housing and electrical contact elements and a plug connector having electrical contacts configured for attachment to a single pair Ethernet cable. The single pair Ethernet cable comprises a first and a second transmission line for conducting data and power. The connector and the plug connector comprise a keying means configured for the plug connector to be unambiguously inserted into the connector in a predetermined direction.

[0012] The bipolar conductor connector system covers shielded and unshielded free and fixed MultiMedia Connectors (MMC) for data transfer at frequencies up to 4000 MHz in case of the connector in shielded form and up to 600 MHz in case of the connector in unshielded form, both with a current carrying capacity up to 8 lines.

[0013] The connector of the bipolar conductor connector system can be used for Single Pair Ethernet (SPE) according to known standards such as IEEE standards, but is not limited to such standardized use. In general, a connector is a device that provides connection and disconnection with a suitable mating component. A plug connector can be defined as a part of a connector system integrated with or intended to be attached to a flexible cable.

[0014] The connector includes a housing. The housing can be formed of a hollow rectangular shell made of an electrically conductive material to minimize crosstalk. A front surface or contact surface of the housing is defined by a front surface of the shell, while a back surface or termination surface of the housing is defined by an exposed back surface of the shell. A top surface and a bottom surface of the shell define an upper surface and a lower surface of the housing, respectively. The housing is typically made of a metal material that is high in strength and heat resistance. Furthermore, each housing is designed as a shield to minimize crosstalk between adjacent housings and / or other electrical or electronic parts such as nearby wire segments. Thus, due to the improved crosstalk performance, the connector designed as a multimedia connector can be used to run applications independently on each pair without any interference from adjacent pairs. The housing is configured to mate with a plug connector along a longitudinal mating axis.

[0015] The connector provides two electrical contact elements, in particular a first electrical contact element and a second electrical contact element, accessible from a first end of the housing, wherein the contact elements are arranged to be electrically connected to a wire pair. The electrical contact elements can be designed as male or female contacts. The two electrical contact elements of each housing of the connector allow for transmission of data and power.

[0016] In one embodiment, the first and second electrical contact elements of the connector can be designed as cylindrical contact pins, connector contacts or electrodes of an electrically conductive material, which are symmetrically arranged in the housing of the connector to achieve a desired impedance. Advantageously, the cylindrical geometry of the electrical contacts provides a circular contact area that avoids degradation of the contact area. The nominal diameter of the electrical contact elements can be about 1 mm in order to allow for transmission of higher currents.

[0017] The housing for a 1-pair connector can be configured to have an outer shape and size, referred to as a form factor, that is less than a quarter of a well-known and most commonly used standardized connector such as an RJ45 or similar connector. Thereby, the 1-pair connector can be used to share a cable with already installed structured cabling. RJ45 is a specific cable termination, in particular a standardized network interface, which defines male and female connectors as well as pin assignments for an eight-wire connector connection.

[0018] The plug connector includes two electrical contacts. The two electrical contacts can be configured to be inserted into a holding piece of a non-conductive material in order to separate the electrical contacts from each other at a defined distance. The arrangement of the two contacts in the holder can be in a symmetrical manner such that the achievable symmetry of the signal transmission is maximized. The symmetrical arrangement is most advantageous for signal transmission since it is less sensitive to disturbances coupled to nearby electrical wires. The holding piece, also referred to as an insert, has two cylindrical through-holes arranged parallel to the longitudinal axis of the housing and configured to hold the first and second electrical contacts, respectively.

[0019] In another embodiment of the present solution, the shield contacts can optionally be arranged to improve cross-talk. This is most advantageous at higher frequencies, higher noise environments and higher data rates with noise constraints. In 4-pair cable systems, this is referred to as cable sharing and all kinds of bundling, independent and parallel operation also require improved cross-talk.

[0020] The housing, the holder and the two electrical contact elements as well as the two electrical contacts are arranged in a way that a predeterminable impedance is achieved. Furthermore, with the present solution, it is possible to keep the distance between the different conductors more or less constant over the entire longitudinal distance of the connector, resulting in a constant impedance.

[0021] The connector is configured to receive a plug-in connector and to hold the plug-in connector in place. The plug-in connector can be inserted into the connector and held in place by a locking mechanism or a snap mechanism or a thread lock. These locks are configured to inhibit longitudinal movement of the mating components of the conductor connector system. Thereby a robust design, reliable use and effortless handling is provided. In the preferred embodiment with a plug-in connector combining two or four holders, each holder having two electrical contacts, one locking mechanism and multiple snap mechanisms are provided, making the plug-in connector easy to handle.

[0022] The keying means for the keying function are arranged in such a way that the plug-in connector is securely held and held in the correct alignment in the connector. For some applications, especially power applications, the orientation of the connected plug relative to the connector is relevant. The keying means avoids that the plug-in connector is inserted in the wrong orientation, thus avoiding damage caused by reversed voltage. The keying means can be designed as a mechanical interface or mating face, e.g. a ridge or a groove, provided on the housing of the connector, with the purpose that the plug-in connector can only be inserted into the housing in a single orientation, so that only the correct electrical contact elements contact each other. In the preferred embodiment, the keying means is provided as a wear corner, positioned depending on the number of bundled connectors and depending on whether the connector is designed as a fixed or a free connector.

[0023] For shielded and unshielded fixed 1-pair connectors, the wear corner can be positioned in the lower left corner, for 2-pair connectors, the wear corner can be the outer right and left upper corners, for 4-pair connectors, the wear corner can be arranged at the outermost position relative to the center of the arrangement of the 4-pair connectors forming a square.

[0024] For shielded and unshielded free 1-pair connectors with a snap or locking means, the wear corner can be positioned on the lower right corner. In case of free 2-pair connectors, the wear corner can be arranged on the outer right and left upper corners. In case of free 4-pair connectors, the worn corner can be arranged at the outermost position relative to the center of the arrangement of the 4-pair connectors forming a square.

[0025] The dual-pole connection system is based on a simple design that combines the advantages of a single plug connector and a bundled connector in a block in a very space-saving manner. According to the present solution, the connectors can be provided in different styles related to the number of pairs, e.g. 1 pair, 2 pairs and 4 pairs.

[0026] For example, 2 pair connectors can be used in a daisy chain configuration of devices in order to interconnect one device to an adjacent device. A daisy chain is a simple way of connecting a network in which devices are connected in series and messages sent over the network travel along the chain from one device to another. In some standards for daisy chain networks, the type of cable used is specified. For example, a certain minimum standard is defined and the cable must be twisted in order to balance the differential signals to reduce or eliminate the effects of interference.

[0027] 4 pair connectors can be used in the design of digital ceiling or other outlet planning arrangements and can operate independently on new or installed 4 pair cable systems with up to four applications. BRIEF DESCRIPTION OF DRAWINGS

[0028] Other features and advantages of the present solution will become apparent from the following description of the non-limiting exemplary embodiments, taken in conjunction with the accompanying drawings, wherein:

[0029] Figure 1a is a schematic front view of a fixed connector configured as a 1 pair connector according to one embodiment;

[0030] Figure 1b is a schematic side view of a fixed connector configured as a 1 pair connector;

[0031] Figure 2a is a schematic front view of a fixed connector configured as a 2 pair connector;

[0032] Figure 2b is a schematic side view of a fixed connector configured as a 2 pair connector;

[0033] Figure 3a is a schematic front view of a fixed connector configured as a 4 pair connector;

[0034] Figure 3b is a schematic side view of a fixed connector configured as a 4 pair connector;

[0035] Figure 4a is a schematic front view of a free connector configured as a 1 pair connector with a snap mechanism;

[0036] Figure 4b is a schematic side view of a free connector configured as a 1 pair connector with a snap mechanism;

[0037] Figure 5a is a schematic front view of a free connector of a pair of connectors configured with a locking mechanism;

[0038] Figure 5b is a schematic side view of a free connector of a pair of connectors configured with a locking mechanism;

[0039] Figure 6a is a schematic front view of a free connector of a pair of connectors configured with a snap mechanism;

[0040] Figure 6b is a schematic side view of a free connector of a pair of connectors configured with a snap mechanism;

[0041] Figure 7a is a schematic front view of a free connector of a pair of connectors configured with a locking mechanism;

[0042] Figure 7b is a schematic side view of a free connector of a pair of connectors configured with a locking mechanism;

[0043] Figure 8a is a schematic front view of a free connector of a pair of connectors configured with a snap mechanism;

[0044] Figure 8b is a schematic side view of a free connector of a pair of connectors configured with a snap mechanism;

[0045] Figure 9a is a schematic front view of a free connector of a pair of connectors configured with a locking mechanism; and

[0046] Figure 9b is a schematic side view of a free connector of a pair of connectors configured with a locking mechanism. DETAILED DESCRIPTION

[0047] Figure 1a and Figure 1b A pair of shielded and unshielded fixed connectors 100 is shown in detail schematically. The connectors 100 are part of a bipolar conductor connector system 1 and include a housing 101 configured as a shell made of an electrically conductive material. The housing 101 acts as a shield to minimize crosstalk to adjacent housings or other electrical or electronic components.

[0048] Two electrical contact elements 102 are arranged, which are designed as two contact pins, connector contacts or electrodes of an electrically conductive material, for example metal. The contact pins 102 are separated from each other and this arrangement is protected against reverse polarity. In the operating state of the connector 100, the contact pins 102 are accessible from the outside of the connector 100, so that a plug connector (not shown in Figures 1, 2 and 3) can be connected to the electrical contact elements 102. Upon insertion of a corresponding plug connector, these contact pins 102 enter the electrical contacts in the form of cylindrical holes in the holder 105a.

[0049] In the one embodiment shown, the holder 105a has two cylindrical holes arranged parallel to the longitudinal axis of the housing 101 and configured as electrical contacts 104, in which the two contact pins 102 are located.

[0050] The plug connector can only be inserted in one single direction. For this purpose, a keying means 103 is provided. In Figure 1a and Figure 1b , the keying function is achieved by the direction and design of the wear angles on the housing 101. Other forms and / or positions of the keying means 103 are also possible, for example grooves or ridges. The keying means prevents the plug connector from being inserted in the wrong direction, in order to avoid damage caused by reverse voltage.

[0051] Figure 2a and Figure 2b Two pairs of fixed connectors are shown schematically, in which two housings 101 are arranged next to each other. In each housing 101, two contact pins 102 are arranged. Depending on the keying means configured as wear angles in the upper left and upper right corners of the connector 100, up to two plug connectors can be inserted in a clear direction.

[0052] Figure 3a and Figure 3b Four pairs of fixed connectors are shown schematically, in which four housings 101 are bundled to form a square with a center. The wear angles of each housing 101 are arranged on the outermost corners relative to the center. This arrangement of the fixed connectors allows up to four plug connectors to be inserted.

[0053] Figure 4a and 4bA free connector, referred to as a plug connector 105, is schematically illustrated, which is designed as a 1 pair plug connector 105 with a snap mechanism 108. The plug connector 105 has a holder 105a, in which two pairs of electrical contacts 104 are symmetrically arranged as holes. The symmetry results in the best achievable signal transmission. When connected to a fixed connector, the metal housing serves as a shielded contact. The snap mechanism 108 comprises resiliently mounted or springing snap elements at two opposite sides of the holder, so that the plug connector 105 can be snap-fitted to the female housing of the corresponding connector 100. For example, the snap elements can be configured as locking buttons with a protruding portion that serves as a locking device. The locking buttons can be configured as a different element than the holder 105a, and when the protruding portion is arranged in an opening provided on the housing, the locking buttons can be snap-fitted to the connector housing.

[0054] Figure 5a and 5b A free connector, referred to as a plug connector 105, is schematically illustrated, which is designed as a 1 pair plug connector with a locking mechanism 107. The plug connector 105 is generally snap-fitted with the connector 100. Thus, using a latch or locking mechanism 107, so that when the latch is depressed, the plug connector 105 is released from the push-fit connection with the connector. The application of pressure to the latch is quick and simple. The locking mechanism 107 comprises a latch 107a in order to engage to a locking portion 107b provided at a corresponding portion of the connector 100, thereby preventing the plug connector 105 from slipping out. The latch 107a is pivotably attached by a resilient U-shaped band, and can be pushed across the mating direction in order to engage with the locking component 107b.

[0055] Figure 6a and 6b A free connector, referred to as a plug connector 105, is schematically illustrated, which is designed as a 2 pair plug connector with a snap mechanism 108. In order to ensure the correct orientation of the plug connector in the corresponding connector 100, a key device 103 is provided as a wear edge compatible with a wear angle provided in the housing 102 of the connector 100. The snap mechanism 108 of each protruding holder can differ from each other in terms of direction, so that the snap mechanisms 108 are respectively arranged on two sides opposite to each other in a horizontal direction and a vertical direction.

[0056] Figure 7a and 7b A 2 pair plug connector 105 is schematically illustrated, which has a wear edge on each holder, and at least one locking mechanism 107 is provided at one of the two plug connectors 105.

[0057] Figure 8a and 8bFour pairs of plug connectors 105 are schematically shown, with a snap mechanism 108 at each of the four retainers of the plug connectors 105.

[0058] Figure 9a and 9b Four pairs of plug connectors 105 are schematically shown, with a snap mechanism 108 at one of the four retainers of the plug connectors 105 and a lock mechanism 107 at another of the four plug connectors 105.

[0059] While the present solution has been illustrated and described in detail in the drawings and foregoing description, such illustration and description is to be considered illustrative or exemplary and not restrictive; the present solution is not limited to the disclosed embodiments. Other embodiments and variations that are obvious to those skilled in the art based on the foregoing description and accompanying drawings will be understood and implemented. In particular, the number of housings in the connector can be other than one, two or four.

Claims

1. A bipolar conductor connector system (1) comprising - a fixed connector (100) having a housing (101) and electrical contact elements (102), and - a plug connector (105) having electrical contacts (104) configured for attachment to a single pair of electrical cables, characterized in that the fixed connector (100) and the plug connector (105) comprise a keying device (103) configured for unambiguous insertion of the plug connector (105) into the fixed connector (100) in a predetermined direction.

2. The bipolar conductor connector system (1) according to claim 1, wherein the housing (101) of the fixed connector (100) is made of an electrically conductive material to minimize crosstalk between adjacent components.

3. The bipolar conductor connector system (1) according to claim 1 or 2, wherein the housing (101) comprises two electrical contact elements (102) to provide data and power transmission.

4. The bipolar conductor connector system (1) according to claim 3, wherein the two electrical contact elements (102) of the fixed connector (100) are configured as cylindrical contact pins arranged symmetrically in the housing (101).

5. The bipolar conductor connector system (1) according to claim 1, wherein, the housing (101) of the fixed connector (100) designed as a 1-pair connector has an outline that is less than a quarter of an RJ45 standardized connector.

6. The bipolar conductor connector system (1) according to claim 1, wherein the electrical contacts (104) of the plug connector (105) are female electrical contacts (104) held in a holder (105a).

7. The bipolar conductor connector system (1) according to claim 1, wherein the keying device (103) comprises mating surfaces configured on the fixed connector (100) and the plug connector (105) such that their connection can only be achieved in one direction.

8. The bipolar conductor connector system (1) according to claim 7, wherein the mating surfaces are designed as a wear angle and a wear edge formed in one predeterminable position.

9. The bipolar conductor connector system (1) according to claim 1, wherein the position of the keying device (103) varies depending on the number of combined housings (101).

10. The bipolar conductor connector system (1) according to claim 1, wherein a fixed connector (100) is included, the fixed connector (100) having one housing (101) for 1 one-pair application, two housings (101) for up to 2 one-pair applications, or four housings (101) for up to 4 one-pair applications.

11. The bipolar conductor connector system (1) according to claim 1, wherein a plug connector (105) is included, the plug connector (105) being configured as a 1-pair plug connector, a 2-pair plug connector, or a 4-pair plug connector to be inserted into the corresponding counterpart fixed connector (100).

12. The bipolar conductor connector system (1) according to claim 1, wherein the plug connector (105) is provided with at least one snap mechanism (108) that can be snap-fitted to the corresponding fixed connector (100).

13. The bipolar conductor connector system (1) according to claim 1, wherein, the plug connector (105) is provided with a locking mechanism (107).

14. The bipolar conductor connector system (1) according to claim 1, wherein, the plug connector (105) comprises two holders (105a), each having two electrical contacts (104) that can be inserted into 2 pairs of fixed connectors (100) or 4 pairs of fixed connectors (100) and held in place by at least one snap mechanism (108).

15. The bipolar conductor connector system (1) according to claim 1, wherein, The plug connector (105) comprises four holders (105a), each holder (105a) having two electrical contacts (104) which can be inserted into the fixed 4-pole connector (100) and held in place by at least one locking mechanism (107).

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