Cover assembly having at least one impedance control structure

Abstract

To provide a cover assembly for at least one coupling position between two electric conductors of a high-frequency data transmission line in order to improve a transmission performance in regard to a signal integrity.SOLUTION: A cover assembly 1 comprises: a protection cover 4; and at least two electric conductors 5 for transmitting an electric signal of a high-frequency data transmission. At least two electric conductors are extended to a transmission direction passing through a protection cover, and is coupled in at least one coupling position 42 positioned in the protection cover so as to be overlapped each other. The protection cover comprises at least one impedance control structure 46 configured to adjust a predetermined value of an impedance of at least one coupling position. The cover assembly comprises a contact carrier 16 that supports at least one of at least the two electric conductors, and the electric conductor supported by a contact carrier includes a plate-like coupling tub 36 as one end part.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a cover assembly, and more particularly to a cover assembly for protecting a coupling between electrical conductors of a high-frequency data transmission line having an operating frequency in the gigahertz range.

Background Art

[0002] In the field of data transmission, a transmission line typically consists of a plurality of components such as connectors, cables, wires, receptacles, etc. These transmission line components are interconnected to establish the necessary signal channels. The interconnection can be achieved by connection means, such as plug and socket mechanisms or permanent joints. The connection means need to provide a reliable electrical contact between the transmission line components. In the case of a permanent joint, reinforcing means surrounding the permanent joint are further provided to improve the mechanical stability of the permanent joint.

[0003] In applications where high-frequency data transmission is required, the connection means and the reinforcing means themselves may adversely affect the characteristics of the signal channel, reducing the signal quality and the transmission performance respectively.

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide means for reliably transmitting high-frequency signals, particularly in the gigahertz range.

Means for Solving the Problems

[0005] This problem is solved by providing at least one impedance control structure in a cover assembly comprising a protective cover and at least two electrical conductors for transmitting electrical signals for high-frequency data transmission. The at least two electrical conductors extend in a transmission direction through the protective cover and are joined to overlap each other at at least one joining position located within the protective cover. The at least one joining position and the protective cover affect the impedance of the at least two electrical conductors. Thus, this problem is solved in particular by providing at least one impedance control structure in the protective cover to adjust the impedance of the at least two electrical conductors to a predetermined value according to the frequency of data transmission. Thereby, the influence of the at least one joining position and the protective cover is compensated for.

[0006] In general, impedance is a property of an electrical conductor that measures the resistance to the flow of an alternating current. Impedance is affected by several factors such as the material and dimensions of the electrical conductor itself, the average relative permittivity of the medium surrounding the conductor (dielectric), and other conductive or capacitive components near the electrical conductor, in particular the relative distance between their respective surfaces.

[0007] During the transmission of an electrical signal from a signal source via a transmission line to a signal receiver (load), if the impedance of the load does not match the impedance of the transmission line (impedance mismatch), signal reflection can occur. Signal reflection is an undesirable phenomenon because it impairs signal integrity. The causes of such impedance mismatch and subsequent signal reflection can be non-linear changes in the cross-section of the electrical conductor of the transmission line, or discontinuities in the material surrounding the electrical conductor as well as sharp bends in the path of the transmission line.

[0008] Therefore, it is preferable to match the impedance of the transmission line to the impedance of the load and eliminate the cause of impedance mismatch. In other words, it is preferable to adjust the impedance of the transmission line to a predetermined value. Such a predetermined value may be the impedance of the load.

[0009] The above solution is preferable because it reduces signal reflection by compensating for at least one cause of impedance mismatch. Therefore, the signal integrity of the transmitted signal is substantially improved, and the reliability of signal transmission is improved.

[0010] The above solution can be further improved by adding one or more of the following optional features. Thus, each of the following optional features is advantageous in itself and can be combined independently of the other optional features.

[0011] According to the first embodiment, one of at least two electrical conductors may be a wire of an electrical cable, preferably a wire of a shielded electrical cable including at least one stripped end. Each of the others of the at least two electrical conductors may be a contact element of a connector, preferably a pin-shaped contact element of a shielded connector. In this embodiment, the wire and the contact element can together form a signal path for high-frequency data transmission.

[0012] As will be described in more detail below, the signal path has an impedance that reaches a predetermined value by means of at least one impedance control structure. Therefore, the cover assembly can function to protect the joint between the shielded electrical cable and the shielded connector.

[0013] More specifically, the wire can include at least one terminal portion, and at least one terminal portion can protrude from at least one stripped end of the shielded electrical cable into the protective cover. The contact element can include at least one coupling portion having at least one coupling tab, and at least one coupling tab can protrude from at least one coupling portion into the protective cover. Further, at least one terminal portion can at least partially overlap at least one coupling tab at at least one coupling position within the protective cover. Further, at least one terminal portion can be at least partially coupled to at least one coupling tab at at least one coupling position within the protective cover.

[0014] According to this embodiment, since the cover assembly can be used in combination with an electrical cable, data transmission can be performed over a longer distance, improving the function of the present invention. Further, according to this embodiment, since the cover assembly can be used in combination with a connector, the application range of the present invention is further expanded.

[0015] Optionally, the cover assembly can include a first wire of the electrical cable, a second wire of the electrical cable, a first contact element of the connector, and a second contact element of the connector. The first wire and the first contact element together form a first signal path, the second wire and the second contact element together form a second signal path, and the first signal path and the second signal path form a pair of signal paths. It is preferable to position the pair of signal paths apart from each other and electrically isolate them from each other. Further, each of the pair of signal paths can be configured to transmit one of the differential pair of signals for high-frequency data transmission.

[0016] As will be described in more detail below, the pair of signal paths have an impedance that reaches a predetermined value by means of at least one impedance control structure. Thus, the cover assembly can function to protect the connection between the shielded Twinax cable and the shielded Twinax connector.

[0017] More specifically, the first wire and the second wire can each include at least one terminal portion, and the terminal portion can protrude away from the electrical cable into the protective cover in a spaced-apart manner. The first contact element and the second contact element can each include at least one coupling portion. Each coupling portion can include at least one coupling tab, and the coupling tab can protrude from the respective coupling portion into the protective cover. At least one terminal portion of the first wire can at least partially overlap at least one coupling tab of the first contact element at a first coupling position within the protective cover, and at least one terminal portion of the second wire can at least partially overlap at least one coupling tab of the second contact element at a second coupling position within the protective cover. Furthermore, at least one terminal portion of the first wire can be at least partially coupled to at least one coupling tab of the first contact element at a first coupling position within the protective cover, and at least one terminal portion of the second wire can be at least partially coupled to at least one coupling tab of the second contact element at a second coupling position within the protective cover.

[0018] According to this embodiment, data transmission that is less susceptible to electromagnetic noise becomes possible by transmitting differential-pair signals.

[0019] In addition, the centerlines of the pair of signal paths may be parallel to each other along the entire length of the cover assembly. More specifically, the wire pitch between the first wire and the second wire may be equal to the contact pitch between the first contact element and the second contact element. This embodiment particularly prevents the spread of wires leading to sharp bends. Thus, at least one possible cause of signal reflection is eliminated, further improving signal integrity.

[0020] According to another embodiment, the protective cover can be overmolded at at least one coupling position and can be formed from an insulating material, preferably an insulating material having a relative permittivity higher than that of air. In addition, the overmolding can extend beyond a part of each of the at least two electrical conductors. More specifically, the at least two electrical conductors can be at least partially embedded within the overmolding.

[0021] With this embodiment, the protective cover can be manufactured by an automated low-pressure overmolding process. Thus, this embodiment contributes to the simplification of the manufacturing process.

[0022] According to an alternative embodiment, the protective cover can include at least two parts that are connected to each other to form the protective cover. More specifically, the protective cover can be formed together by a pre-made pair of cover halves that engage in a form fit. The pre-made pair of cover halves preferably includes a latching mechanism in that at least one latching cam and at least one latching groove are arranged on each of the cover halves, and at least one latching cam of each of the cover halves is configured to engage with at least one latching groove of the other cover half to form a latching connection.

[0023] According to this embodiment, the protective cover can be assembled by an automated pick and place assembly process. Thus, this embodiment provides an alternative that contributes to the simplification of the manufacturing process.

[0024] Optionally, the cover halves may be identical to each other. It is preferable that the cover halves have a male-female design, as this eliminates the need to distinguish between different types of cover halves, further simplifying the manufacturing process.

[0025] In addition or alternatively, the protective cover can include an inner wall that at least partially separates one of the pair of signal paths from the other of the pair of signal paths. This embodiment prevents direct contact between the pair of signal paths and reduces the risk of electrical short circuits.

[0026] In yet another embodiment, at least one impedance control structure may include or be at least one recess on the outer surface of the protective cover. The at least one recess is an impedance control structure that enables easy adjustment of at least one impedance influencing factor, i.e., the average relative permittivity of the dielectric.

[0027] More specifically, in regions where it is necessary to increase the impedance of at least two electrical conductors in order to reach a predetermined value and to compensate for the influence of the protective cover, the recesses can be locally formed on the outer surface of the protective cover. This applies, for example, to regions where at least two electrical conductors are surrounded by an insulating material having a relative permittivity higher than that of air and where at least two electrical conductors exhibit an increased cross-section, for example due to overlap. In such regions, the recesses are spaces filled with air. Since air has a lower relative permittivity than the insulating material, the low average relative permittivity of the resulting dielectric (partially air, partially insulating material) increases the impedance of the at least two electrical conductors.

[0028] Additionally or alternatively, at least one impedance control structure may include or be at least one through-hole of the protective cover that connects at least two outer surfaces of the protective cover. Preferably, the at least one through-hole can extend through the insulating material in a direction perpendicular to the transmission direction as a cylindrical, cubic, or stadium-shaped cavity.

[0029] The at least one through-hole is also an impedance control structure that facilitates easy adjustment of at least one impedance influencing factor, i.e., the average relative permittivity of the dielectric. In combination with embodiments including a pair of signal paths, the at least one through-hole preferably extends between the pair of signal paths. In this way, a space filled with air can be formed between the pair of signal paths, and since air has a lower relative permittivity than the insulating material, a low average relative permittivity of the dielectric and an increased impedance of the pair of signal paths can be obtained. Therefore, in applications where it is necessary to increase the impedance of the pair of signal paths to reach a predetermined value and to compensate for the influence of at least one bonding position and the protective cover, the at least one through-hole can be incorporated.

[0030] Optionally, at least one impedance control structure may include or be at least one side recess on the side surface of the protective cover. Preferably, at least one pair of side recesses can extend symmetrically on two opposing side surfaces of the protective cover. Further, each of the pair of side recesses can extend in the transmission direction along at least the entire length of the bonding position. Further, in a direction parallel to the through-hole, the at least one pair of side recesses can extend along the entire length of the through-hole.

[0031] More specifically, each of the pair of side recesses may be a trapezoidal, cubic, or circular notch in the insulating material of the protective cover that extends perpendicular to the transmission direction and parallel to the through-hole. Preferably, the notch can extend along the entire height of each side surface. The height is the dimension in a direction perpendicular to the transmission direction and parallel to the through-hole.

[0032] Optionally, each of the pair of side recesses can have at least one chamfered edge at the end in the transmission direction. At least one chamfered edge functions as a draft to simplify the demolding step, and due to this chamfered edge, the manufacturability of the side recess during the casting process is improved.

[0033] In yet another embodiment, the at least one impedance control structure may include at least one capacitive element, preferably a conductive capacitive element positioned on at least one outer surface of the protective cover, or may be a conductive capacitive element. More specifically, the at least one capacitive element may be a metal plate positioned or adhered in a retaining groove on at least one outer surface of the protective cover.

[0034] In an embodiment comprising prefabricated pair of cover halves, the at least one capacitive element may instead be at least one metal clip, bent sheet metal part, or braided metal part that holds the prefabricated pair of cover halves together. More specifically, the prefabricated pair of cover halves can be at least partially surrounded by and brought into direct contact with a metal clip, bent sheet metal part, or braided metal part.

[0035] At least one capacitive element is an impedance control structure that adjusts at least one impedance influencing factor, namely the relative distance between the surfaces of at least two electrical conductors and the surface of at least one capacitive element. In particular, by positioning at least one capacitive element on the surface of the protective cover and thus in proximity to at least two electrical conductors, the relative distance is shortened. Thereby, the impedance of at least two electrical conductors is reduced. Thereafter, in an application where it is necessary to reduce the impedance of at least two electrical conductors in order to reach a predetermined value and to compensate for the influence of at least one bonding position and the protective cover, at least one capacitive element can be used. This applies, for example, when an air-filled gap in the protective cover occurs due to manufacturing errors and at least two electrical conductors are located in an area surrounded by air.

[0036] In addition to or instead of the above case, at least one impedance control structure can include using a high dielectric constant insulating material, preferably a material with a relative dielectric constant of 9 to 10, for the protective cover. More specifically, an insulating material mixed with ceramic powder can be used as the high dielectric constant insulating material for the protective cover. By using the high dielectric constant insulating material, a higher average relative dielectric constant of the dielectric (partly air, partly high dielectric constant insulating material) is obtained, so that the impedance of at least two electrical conductors is reduced.

[0037] Optionally, any of the above embodiments of at least one impedance control structure can be aligned with at least one bonding position. More specifically, at least one impedance control structure is near and / or locally limited to the area affected by at least one bonding position, whereby the effect of at least one impedance control structure can be concentrated and maximized.

[0038] According to yet another embodiment of the present invention, the cover assembly can further include a contact carrier that supports at least one of the at least two electrical conductors, and one end of the corresponding electrical conductor freely protrudes from the contact carrier into the material of the protective cover. More specifically, the end portion includes a straight tab fixed and embedded in the protective cover.

[0039] The contact carrier can be at least one separate part that engages with the protective cover in a form - fit manner. For this purpose, the contact carrier can include sockets or slots for receiving tabs or knobs positioned on the protective cover. Alternatively, the contact carrier can be formed as an integral part of the protective cover.

[0040] This embodiment is advantageous in that it further structurally supports at least one of the at least two electrical conductors by the contact carrier.

[0041] According to another embodiment, the cover assembly can be part of a high - frequency data transmission connector that further includes a terminal shield, and the protective cover and the contact carrier of the cover assembly are located within the terminal shield. The terminal shield can include at least one insertion opening for receiving a mating connector, and the mating connector is preferably configured to make electrical contact with at least one of the at least two electrical conductors when inserted into the opening of the terminal shield.

[0042] With this embodiment, the cover assembly can be used in combination with a mating connector, so the application scope of the present invention is further expanded.

[0043] The technical problem is also solved by providing a method for overmolding a joint between at least one wire of a cable and at least one contact element having a protective cover formed from an insulating material, preferably a polyamide. The method includes the steps of providing at least one contact element, providing at least one wire, positioning at least one contact element and at least one wire in a partially overlapping position, joining at least one contact element and at least one wire by, for example, welding, preferably compression welding and / or resistance welding, or by a similar suitable method such as soldering, brazing, etc., surrounding the joint with a mold including at least one core forming at least one impedance control structure in the insulating material, injecting the insulating material into the mold, and removing the mold and at least two cores after the injected insulating material has hardened.

[0044] By this method, the protective cover can be manufactured as an overmolded part, thus providing a means for reliably transmitting high-frequency signals, particularly in the gigahertz range. At the same time, by this method, at least one impedance control structure can be formed in the insulating material of the protective cover. Therefore, the manufacturing time of the overmolded protective cover is shortened.

[0045] The method can be further improved by adding one or more of the following optional steps. Each of the following optional steps is thus advantageous in itself and can be combined independently of the other optional steps.

[0046] In a first embodiment, the method can include the steps of providing at least one contact element, preferably in a 360° accessible orientation, and providing at least one wire, preferably in a 360° accessible orientation.

[0047] By providing at least one contact element and at least one wire in an orientation that allows 360° access, it becomes possible to perform a resistance welding process. In this process, at least one contact element and at least one wire are arranged overlapping between two ceramic spacers and sandwiched between two electrodes, so that current and mechanical force can be generated in the overlapping at least one contact element and at least one wire. Such a resistance welding process has a short cooling time, so productivity is improved. Also, since it can be realized in small-scale applications, a small design becomes possible.

[0048] In another embodiment, the method can include the steps of providing a first contact element, providing a second contact element, providing a first wire, providing a second wire, positioning the first contact element and the first wire in a partially overlapping position to form a first signal path, and positioning the second contact element and the second wire in a partially overlapping position to form a second signal path.

[0049] According to this embodiment, it is possible to manufacture a pair of signal paths configured to transmit each of one of the signals of the differential pair of signals for high-frequency data transmission. Therefore, by transmitting the differential pair of signals, it is possible to realize data transmission that is less susceptible to electromagnetic noise.

[0050] In yet another embodiment, the method can include the step of fixing the first signal path and the second signal path from at least two opposite directions by at least two cores, preferably two opposite directions perpendicular to the transmission direction.

[0051] By fixing the first signal path and the second signal path from at least two opposite directions by at least two cores, the reliability of the overmolding process is improved to prevent unwanted movement of the first signal path and the second signal path during the injection of the insulating material.

[0052] According to another embodiment, the method can include inserting a blade between a first signal path and a second signal path, and the blade is preferably an integral part of one of at least two cores.

[0053] Since the blade functions as an additional or alternative spacer between the first signal path and the second signal path, it can further prevent unwanted movement of the first signal path and the second signal path during the injection of the insulating material. Therefore, the blade can further improve the reliability of the overmolding process.

[0054] Furthermore, with the combination of at least two cores and the blade, at least one through hole can be formed as an impedance control structure in the insulating material of the protective cover simultaneously with the manufacture of the overmolded protective cover itself.

[0055] Hereinafter, exemplary embodiments of the present invention will be described with reference to the drawings. The illustrated and described embodiments are for illustrative purposes only. The combination of features shown in the embodiments can be changed according to the foregoing description. For example, features not shown in the embodiments but described above can be added if the technical effects related to those features are advantageous for a specific application. Conversely, features shown as part of the embodiments can be omitted as described above if the technical effects related to those features are not necessary for a specific application.

[0056] In the figures, elements corresponding to each other with respect to function and / or structure are denoted by the same reference numerals.

Brief Description of the Drawings

[0057]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

DETAILED DESCRIPTION OF THE INVENTION

[0058] First, with reference to the exemplary embodiments shown in FIGS. 1 to 7, the structure of the cover assembly 1 according to the present invention will be described. FIGS. 8 and 9 are used to explain the structure of the connector 2 according to the present invention. FIGS. 10 to 12 are used to explain the method according to the present invention.

[0059] FIG. 1 is a perspective view of a cover assembly 1 according to one possible embodiment of the present disclosure, and the cover assembly 1 includes a protective cover 4 shown in a perspective view. The cover assembly 1 further includes a first wire 6a of the shielded electrical cable 10, a second wire 6b of the shielded electrical cable 10, a first contact element 12a of the connector 2, a second contact element 12b of the connector 2, and a contact carrier 16.

[0060] The protective cover 4 is a substantially cubic portion formed of an insulating material having a relative permittivity higher than that of air. More specifically, the protective cover 4 may be an overmolded portion 18 as shown in the embodiments of FIGS. 1-4.

[0061] The contact carrier 16 is also a substantially cubic portion formed of an insulating material having a relative permittivity higher than that of air. The contact carrier 16 includes a contact portion 20 having a cross-sectional area smaller than that of the protective cover 4 and a bulging portion 22 having a cross-sectional area equal to that of the protective cover 4. The contact carrier 16 may further include a stepped transition portion between the contact portion 20 and the bulging portion 22.

[0062] The first wire 6a and the second wire 6b extend parallel to each other through the shielded electrical cable 10. Each of the first wire 6a and the second wire 6b includes a terminal portion 24 at one end, and this terminal portion 24 projects from the shielded electrical cable 10 and extends in the transmission direction T into the protective cover 4.

[0063] The first contact element 12a and the second contact element 12b extend parallel to each other through the contact carrier 16 and extend in a direction opposite to the transmission direction T into the protective cover 4.

[0064] As shown in FIGS. 1 and 3, the first contact element 12a and the second contact element 12b may each be a conductive spring beam 26 that extends flat along the transmission direction T. The spring beams 26 can be positioned spaced apart from each other. Each of the spring beams 26 can include a contact portion 28 at one end, a coupling portion 30 at the opposite end, and a holding portion 32 between the contact portion 28 and the coupling portion 30.

[0065] The contact portion 28 can have a curved tip 34. The curved tip 34 can be a pin-shaped or arc-shaped portion integrally formed by the material of the corresponding spring beam 26.

[0066] The coupling portion 30 can include a coupling tab 36 that protrudes to the side opposite the transmission direction T as a continuous portion of the spring beam 26. The coupling tab 36 can be a plate-shaped portion integrally formed by the material of the corresponding spring beam 26 and fixedly embedded in the protective cover 4.

[0067] The holding portion 32 can be a straight portion of the corresponding spring beam 26 fixedly held by the contact carrier 16.

[0068] As seen in FIGS. 1 and 2, the first signal path 38a is formed by the first wire 6a and the first contact element 12a together, and the second signal path 38b is formed by the second wire 6b and the second contact element 12b together. More specifically, at the first coupling position 42a, the terminal portion 24 of the first wire 6a overlaps and is coupled to the coupling tab 36 of the first contact element 12a, and at the second coupling position 42b, the terminal portion 24 of the second wire 6b overlaps and is coupled to the coupling tab 36 of the second contact element 12b.

[0069] The first connection position 42a and the second connection position 42b each have a cross-sectional area perpendicular to the transmission direction T, and this cross-sectional area is larger than the respective cross-sectional areas of the first wire 6a, the second wire 6b, the first contact element 12a, or the second contact element 12b. Accordingly, the first connection position 42a and the second connection position 42b each affect the impedance of the first signal path 38a and the second signal path 38b. In addition, the first connection position 42a and the second connection position 42b are both positioned and arranged within the protective cover 4. The insulating material of the protective cover 4 surrounding the first signal path 38a and the second signal path 38b also affects the impedance of the first signal path 38a and the second signal path 38b due to its role as a dielectric. To compensate for the influence on the first connection position 42a, the second connection position 42b, and the protective cover 4, at least one impedance control structure 46 can be incorporated into the protective cover 4.

[0070] For example, at least one impedance control structure 46 can be at least one recess 44 locally formed on the outer surface 40 of the protective cover 4 in a region where the first signal path 38a and the second signal path 38b are surrounded by the insulating material of the protective cover 4 and the first signal path 38a and the second signal path 38b exhibit an increased cross-section. In particular, the at least one recess 44 can create a space filled with air in the region. For this purpose, the at least one recess 44 can be, for example, a notch in the shape of a substantially cube, cylinder, cone, hemisphere, trapezoid, or stadium in the insulating material of the protective cover 4. The notch can extend at least partially towards the first signal path 38a and / or the second signal path 38b side. Furthermore, the notch can extend in another direction, preferably the transmission direction T, along at least the entire length of the first connection position 42a and / or the second connection position 42b.

[0071] Additionally or alternatively, the protective cover 4 can include a through-hole 48 as an impedance control structure 46, and this through-hole 48 extends through the insulating material of the protective cover 4 as a substantially stadia-shaped cavity 50. More specifically, the through-hole 48 can extend in a direction perpendicular to the transmission direction T and connect the upper surface 54 and the lower surface 56 of the protective cover 4. Further, the through-hole 48 can extend between a first coupling position 42a and a second coupling position 42b and can form an air-filled gap 58 therebetween.

[0072] Alternatively, as shown in FIGS. 3 and 4, the through-hole 48 can extend through the insulating material of the protective cover 4 as a substantially cubic cavity 52. Also in this embodiment, the through-hole 48 can extend in a direction perpendicular to the transmission direction T and connect the upper surface 54 and the lower surface 56 of the protective cover 4. Further, the through-hole 48 can extend between a first coupling position 42a and a second coupling position 42b and can form an air-filled gap 58 therebetween.

[0073] As further seen in FIGS. 3 and 4, the protective cover 4 can include a pair of side recesses 60 as an impedance control structure 46, and this pair of side recesses 60 can be incorporated as an additional or alternative to the through-hole 48. In particular, the pair of side recesses 60 can extend symmetrically at two opposing side surfaces 62 of the protective cover 4, preferably at two side surfaces 62 spanning perpendicularly to the upper surface 54 and the lower surface 56. Further, each of the pair of side recesses 60 can extend in the transmission direction T along at least the entire length of the first coupling position 42a and the second coupling position 42b. Further, in a direction parallel to the through-hole 48, the pair of side recesses 60 can extend along the entire length of the through-hole 48.

[0074] More specifically, each of the pair of side recesses 60 may be a trapezoidal notch 64 in the insulating material of the protective cover 4 that extends perpendicular to the transmission direction T and parallel to the through hole 48. The notch 64 preferably extends along the full height of each side surface 62. The height is the dimension in a direction perpendicular to the transmission direction T and parallel to the through hole 48. Due to the trapezoidal shape of the notch 64, each of the pair of side recesses 60 can have two chamfered edges 66 that are aligned along the transmission direction T.

[0075] Figures 5 and 6 show an alternative embodiment of the protective cover 4 that includes two parts 68 that are connected to each other to form the protective cover 4. More specifically, the protective cover 4 can be formed together by a pair of pre-made cover halves 70 that engage in a form fit. The cover halves 70 are identical to each other according to a male-female design and preferably include a latching mechanism 72 in that two latching cams 74 and two latching grooves 76 are arranged in each of the cover halves 70. The latching cams 74 project from their respective cover halves 70 in a direction perpendicular to the transmission direction T and are each configured to engage in a latching connection with one of the two latching grooves of the other respective cover half 70. For this purpose, each latching groove has a shape complementary to the shape of its respective latching cam 74.

[0076] The pair of cover halves 70 can include an impedance control structure 46 in that at least a part of each cover half 70 is formed using a high dielectric constant insulating material. It is preferable that an insulating material mixed with ceramic powder can be used as the high dielectric constant insulating material.

[0077] Each of the pair of cover halves 70 can further include an inner wall 78 that at least partially separates the first signal path 38a from the second signal path 38b. As seen in FIGS. 1 to 4, the inner wall 78 can also be formed as an overmolded part 18.

[0078] FIG. 7 shows another possible embodiment of the impedance control structure 46 in that a prefabricated pair of cover halves 70 is surrounded by two capacitive elements 80. More specifically, the two capacitive elements 80 are two metal clips 82 each formed from a bent sheet metal part 84. Each metal clip 82 includes an upper plate 86, a middle plate 88, and a lower plate 90 arranged in a U-shape.

[0079] More specifically, the upper plate 86 and the lower plate 90 abut and make direct contact with the prefabricated pair of cover halves 70. The middle plate 88 can be divided into at least two parts, and these parts are embedded in corresponding holding grooves 92 on the side surfaces 62 of the prefabricated pair of cover halves 70.

[0080] Alternatively, the capacitive element 80 may be a separate metal plate (not shown) positioned or adhered in a holding groove 92 on at least one outer surface of the protective cover 4. Further, the capacitive element 80 may be a braided metal part (not shown) surrounding the prefabricated pair of cover halves 70.

[0081] As can be seen in FIGS. 1 to 7, the contact carrier 16 and the protective cover 4 are positioned adjacent to each other in the transmission direction T and can be engaged by shape fitting. For this purpose, the protective cover 4 can include two tabs 94 protruding from the protective cover 4 toward the contact carrier 16 side. The contact carrier 16 can include two complementary-shaped slots each configured to receive one of the two tabs 94 of the protective cover 4.

[0082] In the point that the contact carrier 16 includes the tab 94 and the protective cover 4 includes the slot 96, the assignment of the tab 94 and the slot 96 may be reversed.

[0083] FIG. 8 is a cross-sectional view of a high-frequency data transmission connector 2 including a cover assembly 1 and a terminal shield 98, and a protective cover 4 and a contact carrier 16 of the cover assembly 1 are located within the terminal shield 98. The terminal shield 98 can include one insertion opening 100 for receiving a mating connector 102.

[0084] The connector 2 can be further connected to a shielded electrical cable 10, preferably by a crimp connection. For this purpose, the terminal shield 98 can further include a crimp portion 104 at an end opposite to the insertion opening 100. The crimp portion 104 can be formed as an integral part of the terminal shield 98, and the crimp portion 104 can extend coaxially with the shielded electrical cable 10. Further, as can be seen in FIGS. 8 and 9, the crimp portion 104 can be wound around the shielded electrical cable 10 in a circumferential direction C.

[0085] FIG. 10 shows the result of preparing a first contact element 12a and a second contact element 12b in orientations accessible 360°. The first contact element 12a and the second contact element 12b are prepared in orientations accessible 360° in that the coupling tabs 36 of the first contact element 12a and the coupling tabs 36 of the second contact element 12b project freely from the contact carrier 16.

[0086] FIG. 11 shows the result of preparing a first wire 6a and a second wire 6b in orientations accessible 360°. The first wire 6a and the second wire 6b are prepared in orientations accessible 360° in that the terminal portions 24 of the first wire 6a and the terminal portions 24 of the second wire 6b project freely from the shielded electrical cable 10.

[0087] FIG. 12 shows the preparation of the step of surrounding the first signal path 38a and the second signal path 38b with a cast 106 according to an embodiment of the method disclosed in the present invention. In particular, the terminal portion 24 of the first wire 6a is coupled to overlap the coupling tab 36 of the first contact element 12a at the first coupling position 42a. The terminal portion 24 of the second wire 6b is coupled to overlap the coupling tab 36 of the second contact element 12b at the second coupling position 42b.

[0088] Further, FIG. 12 shows the cast 106 including two mold halves 108a, 108b, two cores 110, and a blade 112 in a state ready to surround the first coupling position 42a and the second coupling position 42b. In particular, the blade 112 can be inserted between the first coupling position 42a and the second coupling position 42b. The blade 112 can be positioned on one of the two cores 110 that fix the first coupling position 42a and the second coupling position 42b from two opposite directions perpendicular to the transmission direction T. The two cores 110 and the blade 112 preferably have a combined shape corresponding to the concave shape of the through hole 48. Therefore, the two cores 110 and the blade 112 can together form the through opening 48 of the insulating material of the protective cover 4.

[0089] FIG. 1 shows the result of removing the cast 106 after the injected insulating material has hardened. More specifically, the insulating material is injected into the cast 106 surrounding the first coupling position 42a and the second coupling position 42b. After the injected insulating material has hardened, by removing the cast 106, the protective cover 4 is formed as an overmolded portion 18 having at least one impedance control structure 46, that is, a through hole 48.

Description of Reference Numerals

[0090] 1 Cover assembly 2 Connector 4 Protective cover 5 Electrical conductor 6 Wire 6a First wire 6b Second wire 10 Shielded electrical cable 12 Contact element 12a First contact element 12b Second contact element 16 Contact carrier 18 Overmolded part 20 Contact portion 22 Bulge 24 Terminal portion 26 Spring beam 28 Contact portion 30 Coupling portion 32 Holding portion 34 Curved tip 36 Coupling tab 38 Signal path 38a First signal path 38b Second signal path 40 Outer surface 42 Coupling position 42a First coupling position 42b Second coupling position 44 Recess 46 Impedance control structure 48 Through hole 50 Stadium-shaped cavity 52 Cubical cavity 54 Upper surface 56 Lower surface 58 Air-filled gap 60 Side recess 62 Side surface 64 Notch 66 Chamfered edge 68 Portion 70 Pre-fabricated cover half 72 Latch mechanism 74 Latch cam 76 Latch groove 78 Inner wall 80 Capacitor element 82 Metal clip 84 Bent sheet metal part 86 Upper plate 88 Middle plate 90 Lower plate 92 Holding groove 94 Tab 96 Slot 98 Terminal shield 100 Insertion opening 102 Mate connector 104 Crimping part 106 Mold 108 Mold halves (a, b) 110 Core 112 Blade T Transmission direction C Circumferential direction

Claims

1. A cover assembly (1), The cover assembly (1) comprises: - a protective cover (4); - at least two electrical conductors (5) for carrying electrical signals of high frequency data transmission; Equipped with The at least two electrical conductors (5) extend through the protective cover (4) in a transmission direction (T) and are coupled to each other overlapping at least one coupling location (42) located within the protective cover (4); The protective cover (4) comprises at least one impedance control structure (46) configured to adjust the impedance of the at least one coupling location (42) to a predetermined value; The cover assembly (1) comprises a contact carrier (16) supporting at least one of the at least two electrical conductors (5); One end of the electrical conductor (5) protrudes from the contact carrier (16) into the protective cover (4); The electrical conductor (5) supported by the contact carrier (16) has a flat connecting tab (36) at one end. Cover assembly (1).

2. one of the at least two electrical conductors (5) being a wire (6) of a shielded electrical cable (10); the other of the at least two electrical conductors (5) is a pin-like contact element (12); The wire (6) and the pin-like contact element (12) together form a signal path (38) for transmitting data. A cover assembly (1) according to claim 1.

3. The cover assembly (1) comprises a first wire (6a), a second wire (6b), a first contact element (12a), and a second contact element (12b); the first wire (6a) and the first contact element (12a) together form a first signal path (38a); the second wire (6b) and the second contact element (12b) together form a second signal path (38b); The first signal path (38a) and the second signal path (38b) form a pair of signal paths (38). A cover assembly (1) according to claim 2.

4. the centerlines of the pair of signal paths (38) extend parallel to one another along the entire length of the cover assembly (1); A cover assembly (1) according to claim 3.

5. the protective cover (4) is overmolded onto the at least one bonding location (42) and is formed from an insulating material; A cover assembly (1) according to any one of claims 1 to 4.

6. The protective cover (4) comprises at least two parts (68) connected to each other to form the protective cover (4). A cover assembly (1) according to any one of claims 1 to 4.

7. The at least one impedance control structure (46) comprises at least one recess (44) in an outer surface (40) of the protective cover (4). A cover assembly (1) according to any one of the preceding claims.

8. the at least one impedance control structure (46) includes at least one through hole (48) in the protective cover (4) extending between the pair of signal paths (38); A cover assembly (1) according to claim 3 or 4.

9. The at least one impedance control structure (46) includes at least one side recess (60) in a side (62) of the protective cover (4). A cover assembly (1) according to any one of the preceding claims.

10. The at least one impedance control structure (46) includes at least one capacitive element (80) positioned on at least one outer surface (40) of the protective cover (4). A cover assembly (1) according to any one of the preceding claims.

11. The at least one impedance control structure (46) includes using a high dielectric constant insulating material for the protective cover (4). A cover assembly (1) according to any one of the preceding claims.

12. the at least one impedance control structure (46) is aligned with the at least one coupling location (42); A cover assembly (1) according to any one of the preceding claims.

13. the at least two electrical conductors (5) are overlapping and coupled to one another at the at least one coupling location (42) located within the protective cover (4) by welding, soldering or brazing; A cover assembly (1) according to any one of the preceding claims.

14. A connector (2), The connector (2) is - a cover assembly (1) according to any one of claims 1 to 13, a terminal shield (98), the protective cover (4) and the contact carrier (16) of the cover assembly (1) are located within the terminal shield (98); The terminal shield (98) includes at least one insertion opening (100) for receiving a mating connector (102). Connector (2).

15. A method for overmolding a joint (42) between at least one contact element (12) and at least one wire (6) of a cable (10) with an insulating material, the method comprising the steps of: - providing said at least one contact element (12); - providing said at least one wire (6); - positioning said at least one contact element (12) and said at least one wire (6) in an overlapping position; - coupling said at least one contact element (12) with said at least one wire (6); - surrounding said coupling portion (42) with a mold (106) including at least one core (110) forming at least one impedance control structure (46) in said insulating material; - injecting said insulating material into said mold (106); - removing the mold (106) after the injected insulating material has hardened; The method includes:

16. the step of coupling the at least one contact element (12) and the at least one wire (6) is performed by welding, soldering or brazing; The method of claim 15.

17. The protective cover (4) is formed from two cover halves having the same configuration. A cover assembly (1) according to claim 6.

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