Electrical connector, electrical line and data transmission system
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- ROSENBERGER HOCHFREQUENZTECHNIK GMBH & CO KG
- Filing Date
- 2025-12-10
- Publication Date
- 2026-07-30
Smart Images
Figure EP2025086399_30072026_PF_FP_ABST
Abstract
Description
[0001] Electrical connector, electrical wiring and data transmission system
[0002] The present application claims priority from European patent application No. 25 154 000.1, the contents of which are incorporated herein in full by reference.
[0003] AREA OF INVENTION
[0004] The present invention relates to an electrical connector comprising a contact carrier and several contact elements, each of which is electrically insulated from one another within the contact carrier. Each contact element has a first axial end region configured to electrically and mechanically contact a corresponding electrical conductor of an electrical line.
[0005] The present invention also relates to an electrical line comprising a rail and several electrical conductors, each of which runs in a longitudinal axis direction of the rail and is electrically insulated from each other by the rail.
[0006] Finally, the present invention relates to a data transmission system comprising an electrical conductor and several electrical connectors.
[0007] TECHNICAL BACKGROUND
[0008] Bus systems, particularly differential bus systems, are used in many application areas, such as industry, automotive, and office environments, for data transmission between multiple bus participants. The wiring system of a differential bus system essentially comprises a main differential line, from which a differential branch line extends for each bus participant. Alternatively, the bus participant can also be connected directly to the main differential line without an intermediate differential branch line. Both shielded and unshielded cables are used.
[0009] Figure 1A shows an equivalent circuit for a differential bus system. The transfer characteristics of the differential bus system result not only from the resistive line values RH and GH, the capacitive line values CH, and the inductive line values LH of the individual line segments, but also from the input impedance of each bus participant TN. The input impedance of a bus participant TN, i.e., an electronic module, is determined by an equivalent circuit consisting of a resistive input resistance Rdev, a parasitic capacitance Cdev, and a parasitic inductance Ldev at the differential input of the bus participant TN. In the equivalent circuit of Figure 1A, the following are shown:
[0010] 1A, the bus participant TN shown in the left half is directly connected to the main line of the bus system, while the bus participant TN shown in the right half is connected to the main line of the bus system via a stub line with the resistive conductor layer Rs and Gs, the capacitive conductor layer Cs and the inductive conductor layer Ls.
[0011] In particular, the parasitic capacitance Cdev at the differential input of an electronic assembly, which results from the parasitic properties of the real components of the electronic assembly and the technical properties of the corresponding ideal component, significantly distorts the characteristic impedance of the differential bus. To improve the transmission characteristics of the bus system, the parasitic capacitance Cdev can be compensated by an additional inductance Lc in the two main conductors of the differential bus system, as shown in Fig. 1B. The physical and technical relationships just described for a differential bus system apply equivalently to the less preferred application of a coaxial bus system consisting of an inner and an outer conductor.
[0012] EP 4344454 A1 describes a technical solution in which the additional inductance Lc is achieved by a ferrite core, which is attached to each of the two main conductors of the differential bus system. This technical solution significantly simplifies the assembly process compared to the prior art, in which a coil is traditionally soldered into each main conductor section of the bus system. Furthermore, the use of ferrite cores avoids the weaknesses typically associated with soldering (e.g., cold solder joints).
[0013] For the differential bus system, instead of a cable solution according to EP 4344454 A1, a rail according to EP 3930205 B1 can be used, in the longitudinal direction of which several electrical conductors run, which are electrically insulated from the rail. Threading ferrite cores onto the electrical conductors of the rail is unfortunately not technically feasible.
[0014] This is a situation that needs improvement.
[0015] DESCRIPTION OF THE INVENTION
[0016] Against this background, the present invention is based on the objective of providing an effective compensation for the parasitic capacitance present at the input of the bus participants of the bus system, in particular for a differential bus system, which has a rail and several electrical conductors running in the longitudinal direction of the rail and electrically isolated from each other by the rail.
[0017] According to the invention, this problem is solved by an electrical connector having the features of claim 1 and by an electrical conductor having the features of claim 8.
[0018] Accordingly, the following are planned:
[0019] An electrical connector for electrical and mechanical connection to an electrical line, which has a rail and several electrical conductors, each running in a longitudinal direction of the rail and electrically insulated from each other by the rail.
[0020] wherein the connector has a contact carrier and
[0021] has several contact elements
[0022] which are each held electrically insulated from each other in the contact carrier
[0023] wherein each contact element has a first axial end region which is configured to electrically and mechanically contact the associated electrical conductor of the electrical line,
[0024] wherein at least one contact carrier area of the contact carrier and / or
[0025] at least one additional element of the connector connected to the contact carrier in each case
[0026] a soft magnetic and electrically insulating material, which is a soft magnetic plastic, for guiding a magnetic flux generated (in a plugged state of the electrical connector in the electrical line) by each signal-carrying electrical conductor in a connector-side segment of an associated magnetic circuit
[0027] and
[0028] comprising an electrical conductor for electrical and mechanical connection with multiple electrical connectors
[0029] a rail and
[0030] several electrical conductors
[0031] which each run in a longitudinal axis direction of the rail and
[0032] are electrically isolated from each other by the rail
[0033] wherein a recess for receiving the multiple connectors is formed in the rail in such a way that the multiple electrical conductors can each be electrically and mechanically contacted by each connector,
[0034] wherein at least rail sections of the rail which each border the respective signal-carrying electrical conductors,
[0035] a soft magnetic and electrically insulating material, which is a soft magnetic plastic, in order to guide a magnetic flux generated (in a plugged state of the respective electrical connector in the electrical line) from the respective signal-carrying electrical conductor in at least one rail-side segment of an associated magnetic circuit or to form a correspondingly full-circuit magnetic circuit.
[0036] Furthermore, the invention relates to a data transmission system comprising an electrical conductor and several electrical connectors, each belonging to a bus participant. The electrical connector of the data transmission system has a contact carrier and several contact elements, each of which is electrically insulated from one another within the contact carrier. The electrical conductor of the data transmission system has a rail and several (signal-carrying) electrical conductors, each of which runs along the longitudinal axis of the rail and is electrically insulated from one another by the rail. At least one recess is formed in the rail in which the several connectors are received, with each connector making electrical and mechanical contact with the several electrical conductors.For this purpose, a first axial end region is preferably formed on each contact element, which electrically and mechanically contacts the associated electrical conductor of the electrical line. At least the rail sections of the rail, which each border the respective signal-carrying electrical conductors, have a soft magnetic and electrically insulating plastic that guides a magnetic flux generated by the respective signal-carrying electrical conductor (in the plugged-in state of the respective electrical connector) in a rail-side segment of the associated magnetic circuit.
[0037] According to a first embodiment of the data transmission system, at least one contact carrier area of the contact carrier and / or at least one additional element of the connector connected to the contact carrier each comprises a soft magnetic and electrically insulating plastic that guides a magnetic flux (generated by each signal-carrying electrical conductor in the plugged-in state of the electrical connector) in a connector-side segment of an associated magnetic circuit. The multiple connectors are arranged in the recess along the longitudinal axis of the rail such that, for each signal-carrying electrical conductor, the associated magnetic circuit comprises the corresponding connector-side segment and the corresponding rail-side segment.
[0038] According to an alternative, second variant of the data transmission system, a rail section made of soft magnetic plastic extends beyond the connector, or at least outside a connection area of the connector, in at least one or preferably both transverse directions of a first transverse extension of the connector within the electrical conductor. This rail section forms the corresponding magnetic circuit completely within the electrical conductor for each signal-carrying electrical conductor. The magnetic circuit is thus formed by the rail section by at least substantially 360° – in contrast to the formation of only a rail-side segment, as is the case in the first variant and in the third variant of the data transmission system described below.
[0039] According to an alternative, third variant of the data transmission system, a rail section and an additional component, each made of soft magnetic plastic, extend beyond the connector, or at least outside a connection area of the connector, in at least one or preferably both transverse directions of a first transverse extension of the connector within the electrical conductor. Together, these components form the complete magnetic circuit for each signal-carrying electrical conductor within the electrical conductor. The magnetic circuit is thus incompletely formed by the rail section (i.e., initially only in a rail-side segment) and—in contrast to the first variant of the data transmission system—is completed not by the connector, but by the additional component.The said additional component can be a separate component of the rail, which can preferably be subsequently mounted in the rail.
[0040] The underlying insight / idea of the present invention according to the first variant consists of closing a magnetic circuit by inserting the connector into the recess of the rail. This circuit comprises a soft magnetic connector-side segment of the connector and a soft magnetic rail-side segment of the rail, and the magnetic flux generated by the adjacent electrical conductor of the rail is guided within this circuit. The connector-side segment of the electrical connector is thus designed or configured to form the closed magnetic circuit for each signal-carrying electrical conductor of the electrical line with the rail-side segment of the electrical line. The rail-side segment of the electrical line is designed analogously.The connector is configured to form a closed magnetic circuit for each signal-carrying electrical conductor of the electrical line with the connector-side segment of the electrical connector. According to the second or third variant of the invention, the magnetic circuit can also be formed solely in the electrical line or in the rail adjacent to the contact elements of the connector. In all three variants of the invention, the inductance of the electrical conductor in the area of the connector can be defined and increased when the connector is inserted into the rail.
[0041] Specifically, a data transmission system is to be created consisting of an electrical cable comprising a rail and several electrical conductors running along the longitudinal axis of the rail and electrically insulated by the rail, and an electrically connected connector for each bus participant. Each connector can be inserted into and secured in a recess formed along the longitudinal axis of the rail. The recess is designed such that the electrical conductors of the cable are freely accessible within the recess and can thus be electrically and mechanically contacted by a corresponding contact element of the respective connector.
[0042] The parasitic capacitance at the input of a bus participant is compensated by an increase in the inductive line covering in at least one axial longitudinal section of the two electrical conductors of the electrical line, which is connected to the contact point of the contact elements of the respective connector with the associated electrical conductor of the electrical line in at least one of the two longitudinal axis directions of the rail.
[0043] As already mentioned, the inductive load is increased by guiding the magnetic flux generated by each of the two electrical conductors in a magnetic circuit, which consists of a rail-side segment within the rail and a connector-side segment within the connector.
[0044] If, according to the invention, a magnetizable and electrically insulating material, i.e., in this case the soft magnetic and electrically insulating material, is used in the contact carrier of the individual connectors and in the rail, then not only can the contact elements in the contact carrier of the individual connectors or the electrical conductors in the rail be electrically isolated from each other, but also the inductive conductivity in the electrical conductors of the electrical line in the area of the electrical and mechanical connections of the individual bus participants can be increased.The parasitic capacitance at the inputs of the individual bus participants can be precisely compensated by increasing the inductive load in at least one axial longitudinal section of the two electrical conductors of the electrical line in the area of the electrical and mechanical connection of the individual bus participants. This is achieved by selecting a suitable soft magnetic and electrically insulating material of a suitable axial length for the rail-side segment in the rail and the connector-side segment in the contact carrier of the respective connector. In this case, a soft magnetic plastic is used as the soft magnetic and electrically insulating material, as this material is best suited for the injection molding process of the contact carrier and the rail.
[0045] However, the applicant reserves the right to claim any magnetizable and electrically insulating material in general, instead of a soft magnetic plastic (the term "soft magnetic plastic" may therefore be replaced by the more general term in the claims and description). Possible materials include, for example, soft magnetic ceramics or ferrite ceramics, soft magnetic composites (e.g., polymer-bonded magnetic powder), or soft magnetic glasses.
[0046] The electrical connector is preferably a straight connector whose longitudinal axis, when mated, is aligned with the electrical conductor in the direction of the base of the recess formed in the rail. The bus participant, which is designed as an electrical assembly and in particular includes an electronic transmitter and receiver, is electrically and mechanically connected to the associated connector. The electrical assembly can preferably be arranged outside the recess in the immediate vicinity of the electrical conductor and mechanically connected to the electrical conductor. However, it is also conceivable that the electrical assembly partially projects into the recess or is connected to the connector via, for example, an electrical cable, and thus can be arranged at a distance from both the connector and the electrical conductor.In a less preferred embodiment, the connector can also be angled, so that the electrical assembly is arranged laterally offset from the recess of the rail.
[0047] The mechanical mating interface of the connector must be designed to ensure reliable fixation of the connector in the recess of the rail. Therefore, the cross-sectional profile of the connector must be adapted to the transverse extent of the recess in the rail.
[0048] The electrical interface of the connector must be designed to ensure reliable electrical and mechanical contact between the axial end region of each contact element, referred to here and in the following as the first axial end region of the respective contact element, and the corresponding electrical conductor of the electrical line. The electrical interface of the connector, which is determined by the number, arrangement, and geometric shape of the first axial end region of each contact element projecting from the contact carrier, must be adapted to the number and arrangement of the corresponding electrical conductors in the electrical line to achieve electrical and mechanical contact between the individual contact element of the connector and the corresponding electrical conductor of the electrical line.The electrical and mechanical interface of each connector is preferably identical due to the homogeneity of the electrical and mechanical interface of the electrical conductors along the longitudinal extension of the rail.
[0049] The rail of the electrical conductor can contain both the electrical conductors relevant for the inductance increase according to the invention, which are used for data transmission, and the electrical conductors not relevant for the inductance increase according to the invention, which are used for power supply transmission. The electrical conductors for data transmission can preferably be at least one pair of electrical conductors for transmitting a differential signal each, which are each arranged within the rail and run along the longitudinal axis of the rail. Alternatively or additionally to differential signal transmission, at least one electrical conductor arranged within the rail can be provided, which transmits an asymmetric signal. Finally, the rail can also have a metallic outer coating or a metallic foil to form an outer conductor or...have shielding for the individual inner conductors, thus enabling coaxial or shielded differential data transmission.
[0050] The electrical conductors of the electrical line are preferably arranged within the rail such that they are freely accessible and thus contactable for electrical and mechanical contact via the corresponding contact element of the individual connectors. They can each be received in corresponding recesses or cavities of the rail, which are formed on one of the two side faces and / or on the base of the recess and can each be open in the direction of the recess. If a differential bus system is present, the two electrical conductors of the electrical line can each be arranged on opposite side walls, on the base, or together on one of the two opposite side walls of the recess.
[0051] To form a connector-side segment of a magnetic circuit for each signal-carrying electrical conductor (i.e., each conductor for data transmission in the electrical line) within the connector, guiding the magnetic flux generated by that conductor, the contact carrier incorporates a soft magnetic plastic in at least one contact carrier area. Thus, either the entire contact carrier or at least one contact carrier area can consist of the soft magnetic and electrically insulating material or the soft magnetic plastic, or be made of the soft magnetic and electrically insulating material or the soft magnetic plastic. In this way, a connector-side segment can be formed for each signal-carrying electrical conductor of the rail to guide the corresponding magnetic circuit.Alternatively or additionally to the entire contact carrier, or at least one contact carrier area of the contact carrier, at least one additional element of the connector connected to the contact carrier may comprise or be made of a soft magnetic plastic in order to form a connector-side segment of a magnetic circuit belonging to at least one signal-carrying electrical conductor. The at least one contact carrier area of the contact carrier and / or the at least one additional element made of a soft magnetic plastic may each be composed entirely of a soft magnetic plastic or may also contain sections of air, such as recesses, grooves, feedthroughs, cavities, through holes, blind holes, etc.
[0052] In the following, a soft magnetic plastic is understood to be a plastic that readily magnetizes in an external magnetic field and simultaneously exhibits low remanence. Such magnetic polarization allows for a magnetic flux density many times higher than that in air. The external magnetic field is enhanced by the material permeability of the soft magnetic plastic. Examples of soft magnetic plastics include polyphenylene sulfide (PPS), polyphthalamide (PPA), ethylene butyl acrylate (EBA), and polyamide 12 (PA 12), to which fillers such as soft magnetic ferrites or magnetite can be added to increase magnetic permeability. Soft magnetic plastics according to the invention preferably have a coercive field strength of less than 1000 A / m.
[0053] As already mentioned, the electrical line comprises a rail and several electrical conductors which run in a longitudinal axis direction of the rail and are electrically insulated from each other by the rail.
[0054] The rail can be a profile rail, i.e., a rigid body whose longitudinal extent is a multiple of its transverse extent and whose cross-sectional profile is preferably constant along its longitudinal extent. The profile rail can be manufactured in one piece or in multiple pieces and is preferably produced by an extrusion process.
[0055] The electrical conductors preferably extend along the entire longitudinal extent of the rail. Several connectors can be inserted into the recess in the rail, each of which can be electrically and mechanically connected to a bus participant designed as an electrical assembly. The axial position of each connector along the rail is determined by the application-specific positioning of the individual bus participants.
[0056] With regard to the individual geometric shapes and the individual material-technical designs of a rail for transmitting a high-frequency electromagnetic wave, reference is made to EP 3 930205 B2, the disclosure of which is hereby fully incorporated into the patent application.
[0057] In order to form at least one rail-side segment of a magnetic circuit or a complete magnetic circuit for guiding the magnetic flux generated by the respective electrical conductor in the rail for each signal-carrying electrical conductor, i.e., for each electrical conductor for data transmission, at least rail areas, i.e., reduced transverse areas of the rail compared to the total transverse extent of the rail, which each border the individual signal-carrying electrical conductors, have a soft magnetic plastic or are made of a soft magnetic plastic.
[0058] Since the individual connectors can be received at any axial position in the recess of the rail, the rail areas adjacent to signal-carrying electrical conductors, made of a soft magnetic plastic, preferably extend over the entire longitudinal extent of the rail.
[0059] The rail's construction from a soft magnetic plastic can be limited to at least certain sections of the rail or extend over the entire rail, as will be explained in detail below. The soft magnetic plastic used in at least the individual sections of the rail can preferably correspond to the soft magnetic plastic used in at least one contact carrier area of the contact carrier and / or in at least one additional element of the connector connected to the contact carrier. This ensures homogeneous, i.e., closed, guidance of the generated magnetic flux in a magnetic circuit comprising a connector-side segment and a rail-side segment. In a less preferred embodiment, however, the use of different soft magnetic plastics in the rail and the connector is also conceivable.
[0060] Advantageous designs and further developments result from the further sub-claims as well as from the description with reference to the figures in the drawing.
[0061] It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or on their own, without leaving the scope of the present invention.
[0062] In a preferred embodiment of the connector according to the invention, the soft magnetic plastic can have a permeability of preferably at least 20, more preferably at least 50, and most preferably at least 80. The higher the permeability of the soft magnetic plastic, the higher the flux density achievable in the contact carrier or in the additional element of the connector, thus improving the guidance of the magnetic flux in the contact carrier or in the additional element of the connector. A permeability that is too low leads disadvantageously to an unfavorable increase in the transverse area of the connector.
[0063] The parameter ranges mentioned above for the permeability of the soft magnetic plastic used in a preferred embodiment of the connector according to the invention can also be applied analogously to the soft magnetic plastic in the rail of a preferred embodiment of the electrical conductor according to the invention. In a further preferred embodiment of the connector according to the invention, the coercive field strength of the soft magnetic plastic can be less than 1000 A / m. Such a limitation of the coercive field strength of the soft magnetic plastic advantageously leads to small hysteresis losses during remagnetization due to a high-frequency signal in the electrical conductors.The parameter range mentioned above for the coercive field strength of the soft magnetic plastic used in a further preferred embodiment of the connector according to the invention can also be applied analogously to the soft magnetic plastic in the rail of a preferred embodiment of the electrical conductor according to the invention.
[0064] To achieve electrical and mechanical contact with a sufficiently high contact pressure between the individual conductors of the electrical cable or rail and the contact elements of the connector, in a further preferred embodiment of the connector, the first axial end region of each contact element can be elastically designed. If the electrical conductors to be contacted are arranged in the side surfaces of the recess in the rail, the contact elements can exhibit elasticity directed laterally to the longitudinal axis of the connector. If, on the other hand, the electrical conductors to be contacted are arranged in the base surface of the recess in the rail, the contact elements for end-face contact can exhibit elasticity directed in the longitudinal direction of the connector.In the aforementioned cases, the contact elements, when the connector is connected to the electrical conductor, can preferably be arranged in the same axial position along the longitudinal axis of the recess in the rail within the connector. If the electrical conductors are arranged on the same side wall of the recess, particularly in the case of a differential bus system, the associated contact elements, when the connector is connected to the electrical conductor, can preferably be arranged axially offset along the longitudinal axis of the recess in the rail within the connector.
[0065] In a preferred embodiment of the connector according to the invention, the contact carrier areas and / or the additional elements, each made of the soft magnetic plastic, can extend in at least one of the two transverse directions of a transverse extension of the connector beyond a connection area of the connector in which the contact elements are arranged within the connector. The transverse extension of the connector is here and in the following referred to as the first transverse extension of the connector and, in a mated state of the connector in the rail, is oriented in the longitudinal direction of the rail.
[0066] Thus, in at least one lateral area of the connector outside the connection area, in combination with an adjacent section of the rail, a magnetic circuit can be implemented to guide the magnetic flux generated by a signal-carrying electrical conductor of the electrical line, thereby increasing the inductive load in the data transmission system outside the connector's connection area. In addition to the contact carrier areas of the connector or the connector's auxiliary elements, which each feature the soft magnetic plastic, the connection area of the connector located between them can also feature the soft magnetic plastic, in particular the same soft magnetic plastic. Alternatively, the connection area of the connector can also feature a plastic other than a soft magnetic plastic.Finally, the connection area of the connector, with the exception of the contact elements, can be at least partially and in extreme cases completely devoid of material, i.e., represent an area containing air.
[0067] In a particularly preferred embodiment of the connector according to the invention, the respective contact carrier area or the respective additional element, each comprising the soft magnetic plastic, can extend beyond the contact elements, i.e., outside the connection area of the connector, in both transverse directions of the first transverse dimension of the connector. Furthermore, the contact carrier area or the additional element, each comprising the soft magnetic plastic, can preferably extend over a substantially equal length in both transverse directions of the first transverse dimension of the connector.While the first requirement results in a bilateral increase in the inductive load relative to the connection point of the bus participant connected to the connector, the combination of the first and last requirements results in a symmetrical increase in the inductive load relative to the connection point and thus optimal compensation of the parasitic capacitance at the connection point. It should be noted here that the cross-sectional area or profile of the connector in the direction of the side walls of the recess in the rail, which is referred to here and in the following as the second cross-sectional area or profile of the connector, can preferably be constant over the entire first transverse area of the connector.
[0068] In an optional further development of the electrical conductor or in a variant of the data transmission system, in addition to the rail sections of the rail having the soft magnetic plastic and, if applicable, as an alternative to the contact carrier sections or additional elements of the electrical connector having the soft magnetic plastic, it can also be provided that outside the connector or beyond the contact elements of the connector, in at least one, preferably in both transverse directions of the first transverse extension, rail sections and / or additional components of the rail extend, which each adjoin the respective signal-carrying electrical conductors and which each have the soft magnetic plastic.
[0069] Either the entire rail or at least the aforementioned rail sections can be made of or comprised of the soft magnetic plastic. Alternatively or additionally to the entire rail or at least one rail section, at least one additional component connected to the rail can be made of the soft magnetic plastic (e.g., an additional component that can be inserted separately into the rail and placed in a space between two adjacent connectors in the rail) in order to form another rail-side segment of the magnetic circuit.The at least one rail section and / or the at least one additional component can each either be composed entirely of a soft magnetic plastic or also contain partial areas of air, for example recesses, grooves, feedthroughs, cavities, through holes, blind holes, etc.
[0070] Finally, each contact element can preferably have a further axial end region, which is referred to here and in the following as the second axial end region. The second axial end region of each contact element can be configured to electrically and mechanically contact a corresponding mating contact element of a mating connector corresponding to the connector or an electrical conductor of an electrical assembly. The mating connector can be designed as a cable connector that is electrically and mechanically connected to an electrical cable, which is connected to the electrical assembly of the bus participant.Alternatively, the mating connector can be designed as a housing connector that is installed in the housing of the electrical assembly of the bus participant, or as a printed circuit board connector that electrically and mechanically contacts a printed circuit board of the electrical assembly of the bus participant.
[0071] Instead of forming a plug-in interface, the second axial end region of each contact element can be connected to the electrical conductor of an electrical cable by a material or form-fit connection, or to a conductor track, contact surface, or electrically conductive feedthrough of a printed circuit board by a material, force, or form-fit connection. The electrical cable and the printed circuit board can each be electrically and mechanically connected to the electrical assembly of the bus participant or be part of the electrical assembly of the bus participant.
[0072] In a first embodiment of the electrical conductor according to the invention, the rail of the electrical conductor can have the soft magnetic plastic or be made of the soft magnetic plastic across its entire cross-sectional profile. In this case, not only the rail sections adjacent to the individual electrical conductors for data transmission can have a soft magnetic plastic, but also rail sections adjacent to the individual electrical conductors for power transmission, which do not necessarily have to be made of a soft magnetic plastic.
[0073] In this way, the entire rail can be advantageously manufactured from the soft magnetic plastic in a single extrusion process. Additional assembly or joining processes, as required for a multi-part rail, can be avoided. Only the electrical conductors need to be snapped into the corresponding cavities of the rail, and in the case of shielded data transmission, the outer surface of the rail must also be coated with a metallic layer or covered with a metallic foil.
[0074] In a second embodiment of the electrical conductor according to the invention, the rail can be formed in multiple parts. The rail can have an outer rail element and at least one inner rail element, each of which is arranged within the outer rail element. The at least one inner rail element can each comprise the rail section adjacent to the respective electrical conductor for data transmission and can be made of, or comprise, the soft magnetic plastic. The second rail element can comprise an electrically insulating material other than the soft magnetic plastic. In this respect, cavities for the electrical conductors for power transmission can be formed in the second rail element. If the electrical conductor has a shield, the second rail element can preferably have a metallic outer coating.be covered by a metallic foil. Alternatively or additionally, at least one first rail element can also have a metallic coating or a metallic foil on its outer surface for shielding purposes.
[0075] In the case of multiple inner rail elements, preferably two, each inner rail element can comprise the rail section that adjoins an associated electrical conductor for data transmission and that comprises a soft magnetic plastic. In the case of a single inner rail element, the single inner rail element can comprise multiple rail sections, preferably two, each adjoining an associated electrical conductor for differential data transmission and each comprising a soft magnetic plastic. These rail sections can be integrally connected within the single inner rail element via a further rail section that also comprises a soft magnetic plastic.
[0076] Each of the rail elements can preferably be manufactured in a separate extrusion process. After inserting the individual electrical conductors into the corresponding cavities of the at least one inner rail element and the outer rail element, the individual rail elements can be joined together in a final assembly process. The advantage of the second embodiment of the electrical conductor according to the invention lies in the use of a more economical plastic for the outer rail element, which does not necessarily have to be soft magnetic.
[0077] The invention further relates to a data transmission system comprising an electrical conductor and several electrical connectors according to the invention. The multiple connectors are each arranged in the recess of the rail along the longitudinal axis such that, for each signal-carrying electrical conductor, i.e., for each electrical conductor for data transmission, the associated magnetic circuit comprises the corresponding connector-side segment and the corresponding rail-side segment.
[0078] The technical features, effects, and advantages mentioned previously and subsequently regarding the electrical connector and the electrical cable also apply equivalently to the data transmission system, and vice versa. The data transmission system according to the invention, which can be configured as a bus system, preferably a differential bus system, enables, in particular, data transmission between several bus participants, each of which preferably contains an electrical assembly for sending and receiving a high-frequency data signal. The electrical assembly of the bus participants is preferably wired to a corresponding connector, which is inserted into the recess of the rail of the electrical cable and is electrically and mechanically connected to the electrical conductors for data transmission.In a less preferred embodiment, the electrical assembly of each bus participant can be wirelessly connected to the corresponding connector via a radio interface. A high-frequency electromagnetic wave is transmitted between the two communicating bus participants in the electrical line, particularly along the electrical conductors of the differential bus system. Regarding access to the data transmission system by bus participants wishing to transmit and the equalization of any interference occurring in the high-frequency electromagnetic wave, reference is made to EP 3930205 B1.
[0079] The individual connectors are each arranged in a corresponding axial position within the recess of the electrical conductor rail such that a closed magnetic circuit is formed for each signal-carrying electrical conductor of the electrical conductor, which can guide the magnetic flux generated by the respective signal-carrying electrical conductor. In a first variant of the data transmission system, each closed magnetic circuit comprises a corresponding connector-side segment in a contact carrier area and / or in an additional element of the connector, and a corresponding rail-side segment in a rail area of the rail, each made of a soft magnetic plastic. In a second and third variant of the data transmission system, the closed magnetic circuit comprises only rail-side segments, respectively.is formed solely on the rail side, in particular in at least one transverse axis direction of the first transverse extension of the connector beyond the connector.
[0080] In a preferred embodiment of the data transmission system according to the invention, the at least one contact carrier area and / or the at least one additional element for each signal-carrying electrical conductor of the data transmission system can each be spaced apart from two wall segments of the recess in the respective rail area by a gap. The two wall segments are arranged opposite each other relative to the respective electrical conductor.
[0081] In this way, at least one associated closed magnetic circuit can be formed for each signal-carrying electrical conductor, which encloses the respective signal-carrying electrical conductor and which consists of the connector-side segment, the rail-side segment and two gaps between the connector-side segment and the rail-side segment.
[0082] To form a closed magnetic circuit in which the magnetic flux generated by the signal-carrying electrical conductor can be guided, the individual gap can be a maximum of 0.15 mm, i.e., smaller than 0.15 mm, and preferably a maximum of 0.1 mm, i.e., preferably smaller than 0.1 mm. Particularly preferably, the gap can be a closed gap. In the latter case, the connector-side segment of the connector directly and immediately contacts the rail-side segment of the rail, so that the magnetic resistance in the magnetic circuit is minimized. In the latter case, the connector can particularly preferably be inserted completely and without gaps in the recess of the rail over the entire insertion depth of the connector and / or over the entire first transverse extent of the connector.
[0083] In a further preferred embodiment of the data transmission system according to the invention, at least one spring arm, preferably two spring arms, can be formed on the connector, each of which contacts a corresponding side wall of the recess in the rail. This design of the connector allows it to be fixed to the rail in the recess by means of a force-fit connection. Furthermore, the force-fit fixing of the connector to the rail by means of at least one spring arm enables gap-free mechanical contact between the connector and the rail. In this way, with a suitable design and arrangement of the at least one spring arm relative to the rail or relative to an electrical conductor, a corresponding magnetic circuit with at least one closed gap can be reliably realized.
[0084] As an alternative to friction-fit fixing of the connector to the rail, a positive-locking fixing of the connector to the rail can also be achieved using at least one spring arm of the connector, provided that the at least one spring arm can be engaged in a corresponding detent recess in a corresponding side wall of the recess in the rail. In the preferred case of two spring arms formed on the connector, these can be formed on opposite sides of the connector in order to be fixed to opposite side walls of the recess in the rail by friction or positive locking. It should be mentioned here that the connector can alternatively also be inserted, fixed, and released again by means of an interference fit in the recess in the rail.
[0085] In the data transmission system according to the invention, each connector can be connected to a high-impedance electrical assembly of the associated bus participant, i.e., to an electrical assembly whose input impedance is greater than 1000 Ω. In particular, the input impedance of the respective electrical assembly can have a capacitive component. The capacitive component of the input impedance at the input of the respective electrical assembly, which is connected to the second axial end regions of two contact elements of an associated connector, is compensated by an increased inductive conduction permeability in the two associated signal-carrying electrical conductors in the axial insertion area of the associated connector.The increase in the inductive conductivity in the two signal-carrying electrical conductors is formed by a magnetic circuit belonging to each signal-carrying electrical conductor, which comprises a rail-side segment and a connector-side segment, each made of a soft magnetic plastic.
[0086] The capacitive component in the input impedance of a given electrical assembly can be partially compensated if the inductive load in the two associated signal-carrying electrical conductors is increased only in one longitudinal axis direction of the rail relative to the axial position of the associated connector in the rail or relative to the connection area of the connector to the electrical conductors of the rail.
[0087] Complete compensation of the capacitive component in the input impedance of a given electrical assembly can be achieved by increasing the inductive conductivity in both associated signal-carrying electrical conductors in both longitudinal directions of the rail relative to the axial position of the associated connector or relative to the connector's connection area to the rail's electrical conductors. Furthermore, with complete compensation, the rail-side segment and the connector-side segment of the magnetic circuit belonging to the respective signal-carrying electrical conductor extend over essentially the same axial length in both longitudinal directions of the rail relative to the axial position of the associated connector in the rail or relative to the connector's connection area to the rail's electrical conductors.
[0088] The above embodiments and further developments can be combined with one another as appropriate. Further possible embodiments, further developments, and implementations of the invention also include combinations of features of the invention described previously or subsequently with regard to the exemplary embodiments, even if not explicitly mentioned. In particular, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention.
[0089] CONTENT OF THE DRAWING
[0090] The present invention will be explained in more detail below with reference to the exemplary embodiments shown in the schematic figures of the drawing. These figures show:
[0091] Fig. 1A shows a representation of a line model for a differential bus system according to the state of the art,
[0092] Fig. 1B shows a representation of a line model for a differential bus system with compensation of a parasitic capacitance according to the state of the art.
[0093] Figs. 2A, 2B show an exploded view of an unassembled data transmission system according to the invention and an isometric view of an assembled data transmission system according to the invention.
[0094] Figs. 3A, 3B are isometric views and side views of a first embodiment of a connector according to the invention; Figs. 3C, 3D are cross-sectional views and enlarged sections of a data transmission system according to the invention with a connector according to the invention as shown in Figs. 2A and 2B and a first embodiment of an electrical conductor according to the invention.
[0095] Figs. 4A, 4B show a cross-sectional view and an enlarged section of a connector according to the invention as shown in Figs. 2A and 2B in a second embodiment of an electrical conductor according to the invention.
[0096] Figs. 5A, 5B show a cross-sectional view and an enlarged section of a second embodiment of a connector in a third embodiment of an electrical conductor according to the invention.
[0097] Figs. 6A, 6B show a cross-sectional view and an isometric view of a third embodiment of a connector according to the invention in a fourth embodiment of an electrical conductor according to the invention.
[0098] Figs. 6C, 6D show two enlarged sections of the connector and electrical conductor according to the invention as shown in Figs. 5A and 5B.
[0099] Fig. 7 shows a cross-sectional view of a fourth embodiment of a connector according to the invention,
[0100] Fig. 8 shows an isometric representation of a fifth embodiment of a connector according to the invention;
[0101] Fig. 9A, 9B shows a cross-sectional view of a data transmission system according to the invention and a perspective view of a soft magnetic accessory component of an electrical line in a sixth embodiment.
[0102] The accompanying figures are intended to provide a further understanding of the embodiments of the invention. They illustrate embodiments and, in conjunction with the description, serve to explain the principles and concepts of the invention. Other embodiments and many of the advantages mentioned will become apparent with reference to the drawings. The elements of the drawings are not necessarily shown to scale.
[0103] In the figures of the drawing, identical, functionally equivalent and similarly acting elements, features and components - unless otherwise stated - are each provided with the same reference symbols.
[0104] The following section describes the figures in a coherent and comprehensive manner. DESCRIPTION OF EXAMPLES OF EXECUTION
[0105] Figures 2A and 2B show a data transmission system 1 according to the invention in an unassembled and an assembled state. By way of example, a single bus participant 2 of the data transmission system 1 is shown, which is electrically and mechanically connected to the electrical line 4 of the data transmission system 1 via a connector 3. Typically, several bus participants 2 are connected to such a data transmission system 1 via associated connectors s and carry out data communication via the data transmission system 1. The electrical line 4 has an electrically insulating rail 5, which is designed as a profile rail along a longitudinal axis LA.In the longitudinal direction of the rail 5, two electrical conductors 6 are preferably guided at a distance from each other and electrically insulated. These conductors are configured to transmit a differential data signal, preferably a differential high-frequency data signal, between the individual bus participants 2. A recess 7 is formed in the rail 5 along its longitudinal axis LA, into which the individual connectors 3 can be received and mechanically fixed. To fix the bus participant 2 to the electrical conductor 4, preferably to the rail 5 of the electrical conductor 4, at least one locking element 8, preferably two locking elements 8 at the axial ends of the bus participant 2, is provided on the bus participant 2. These locking elements engage in corresponding locking grooves in the recess 7 in the rail 5.Within the recess 7 of the rail 5, electrical contact is also made between the electrical conductors 6, which transmit the differential data signal, and the associated contact elements 12 of the individual connectors 3.
[0106] The following figures illustrate the individual embodiments of an electrical connector 3 and an electrical cable 4.
[0107] Figures 3A to 3D show a first embodiment of an electrical conductor 4 and an associated first embodiment of an electrical connector 3:
[0108] In the first embodiment of the electrical conductor 4 according to Fig. 3C, the two electrical conductors 6, which transmit the differential data signal, are arranged on two opposite side walls of the recess 7. The two electrical conductors 6 are arranged on the side walls of the recess 7 such that they are accessible for lateral contact by the individual connectors 3, which are received in the recess 7.
[0109] In the first embodiment of the electrical conductor 4, the rail 5 has an outer rail element 5i with a preferably rectangular base profile and an inner rail element 52, which is arranged within a transverse section of the outer rail element 5i. The recess 7 of the rail 5 thus comprises a section 7i of the recess 7, which is located within the outer rail element 5i and outside the inner rail element 52, and a further section 72 of the recess 7, which is located within the outer rail element 5i and within the inner rail element 52 (see the dashed lines in Fig. 2B). The recess 7 of the rail 5 extends along a transverse axis Q of the rail 5, which is oriented orthogonally to the longitudinal axis LA of the rail.Orthogonal to the transverse axis QA and the longitudinal axis LA of the rail 5, a first pair of grooves 9 for receiving the two electrical conductors 6 for data transmission and a second pair of grooves 10 for receiving a further pair of electrical conductors (not shown) that transmit the power supply to the individual bus participants 3 are formed laterally in the outer rail element 5i, starting from the recess 7. Both the first pair of grooves 9 and the second pair of grooves 10 extend along the longitudinal axis LA of the rail. The transverse section of the outer rail element 5i, in which the inner rail element 52 is preferably positively engaged in the outer rail element 5i, extends over the further section li of the recess 7 and the adjacent pair of grooves 9.
[0110] The two electrical conductors 6 for transmitting the differential data signal are positively locked in the inner rail element 52 to two opposite side walls of section li of the recess 7 belonging to the inner rail element 52. Furthermore, the two electrical conductors 6 are arranged in the inner rail element 52 such that a specific surface area of the two electrical conductors 6 is accessible from the recess li of the inner rail element 52 and can be contacted by the contact elements 12 of the connector 3.
[0111] The outer rail element 5i can be made of any electrically insulating plastic, preferably a thermosetting or thermoplastic plastic. The inner rail element 52, on the other hand, is made of a soft magnetic plastic.
[0112] A first embodiment of the connector 3 is shown in the isometric representation of the Fig.
[0113] 3A and the side view in Fig. 3B:
[0114] In the first embodiment of the connector 3, the contact carrier 11, like the inner rail element 52, is made entirely of a soft magnetic plastic, preferably the same soft magnetic plastic as the inner rail element 52. A pair of contact elements 12 for contacting the two electrical conductors 6 is fixed in the contact carrier 11. This fixation is achieved, for example, by means of fixing pins 13, preferably formed integrally on the contact carrier 11, which pass through a through-hole 14 formed in each contact element 12 and preferably clamp the respective contact elements 12 to the contact carrier 11 in a positive-locking manner. The two contact elements 12 are preferably arranged in a central region of the connector 3, which is also referred to as the connection region 28 of the contact carrier 11, in the direction of a first transverse axis Qsi of the connector 3.Furthermore, the contact elements 12 are arranged in a lateral end region of the connector 3 in the direction of a second transverse axis QS2 of the connector 3, which is orthogonal to the longitudinal axis Ls and to the first transverse axis QS1 of the connector 3, such that electrical and mechanical contact between the individual contact element 12 of the connector 3 and the associated electrical conductor 6 of the rail 5 is possible. To achieve sufficient contact pressure between the two contact elements 12 and the associated electrical conductors 6, an axial end region of the respective contact element 12, which is referred to here and in the following as a first axial end region 15 of the respective contact element 12, is elastically designed, preferably as a spring tab, as can be seen in particular from the enlarged view of the contacting in Fig. 3D.
[0115] At a further axial end region of the two contact elements 12, which is referred to here and in the following as the second axial end region 16, electrical and mechanical contact is made with associated mating contact elements of a mating connector or with electrical conductors or electrical contacts of an electrical assembly 17 of the bus participant 3. In Fig. 3C, the two contact elements 12 of the connector 3 are electrically and mechanically connected to metallic feedthroughs 18 of an electrical assembly 17 designed as an electrical circuit board. All possible forms of force-fit, material-fit, or form-fit connection are conceivable. The electrical assembly 17, designed as an electrical circuit board, is arranged in a housing 19 of the bus participant 3, which preferably has a housing base 19i and a housing cover 192 that can be removed for inspection.The housing body 19i has a mechanical interface 19s into which the connector 3 can be plugged.
[0116] For the mechanical fixation of the connector 3 in the rail 5, two axially offset pairs of locking hooks 20 are formed at each of the two lateral end regions of the connector 3, particularly at the two side walls of the connector 3, relative to the longitudinal axis Ls of the connector 3 in the direction of the second transverse axis QS2 of the connector 3. Each pair of locking hooks engages in a corresponding pair of locking recesses. The pairs of locking recesses can be formed, for example, by the pair of grooves 10, as shown in Fig. 3C, in which the electrical conductors 7 for transmitting the power supply can be arranged. The formation of two axially offset pairs of locking hooks 20 advantageously prevents undesired tilting of the connector 3 about the second transverse axis Qs2 of the connector 3 in the recess 7 of the rail 5.
[0117] If the individual connector 3 is received in the recess 7 of the rail 5 and the two electrical conductors 6 are in a signal-carrying state, a magnetic circuit 22 can form around each electrical conductor 6 to guide the magnetic flux generated by the signal-carrying electrical conductor 6. This magnetic circuit 22 encloses the respective electrical conductor 6, as can be seen in the illustration in Fig. 3D, which is an enlargement of the circular section B from Fig. 3C. Due to the soft magnetic plastic of the contact carrier 11, the magnetic circuit 22 has a connector-side segment 22i (dashed segment line of the magnetic circuit 22) and, due to the soft magnetic plastic of the inner rail element 52, a rail-side segment 222 (dotted-dashed segment line of the magnetic circuit 22).With the exception of a possible small gap 23 between the connector 3 and the inner rail element 52, the magnetic flux of the two electrical conductors 6 is guided in a closed magnetic circuit 22. The axial end 24 of the connector 3 can preferably be chamfered to allow the connector 3 to be inserted centered into the recess 7 of the rail 5. The axial end 24 of the connector 3 can also be slotted in the longitudinal axis Ls of the connector 3, thus forming two spring arms 24'. These two spring arms 24' force-fit the axial end 24 of the connector 3 laterally against the side wall of the recess li of the inner rail element 52, minimizing or eliminating the gap between the connector 3 and the inner rail element 52.
[0118] In a second embodiment of the electrical conductor 4 according to Figs. 4A and 4B, the inner rail element 52 is designed in two parts and has a first inner rail element 52 1 , in which one electrical conductor 6 is arranged, and a second inner rail element 52 2on, in which the other electrical conductor 6 is arranged. The associated connector 3 corresponds to the first embodiment of the connector 3 in Figures 3A to 3D. The magnetic circuit 22 for guiding the magnetic flux belonging to the respective electrical conductor 6 in the embodiment of the data transmission system 1 according to Figures 4A and 4B corresponds essentially to the magnetic circuit 22 of the embodiment of the data transmission system 1 according to Figures 3A to 3D. With regard to the technical features of the data transmission system 1 in Figures 4A and 4B, reference is made to the description of the technical features of the data transmission system 1 in Figures 3A to 3D.
[0119] In a third embodiment of the electrical conductor 4 according to FIGS. 5A and 5B, the two electrical conductors 4 are each arranged on the base surface of the recess 7 of the rail 5, in particular on the base surface of section li of the recess 7 belonging to the inner rail element 52. The contact between the contact elements 12 of the connector 3 and the associated electrical conductors 4 is thus each designed as an end-face contact.
[0120] In a third embodiment of the electrical conductor 4 according to Figures 6A to 6D, quasi-coaxial data transmission is achieved by the fact that the rail 5 of the electrical conductor 4 carries an inner electrical conductor and an outer electrical conductor. The inner electrical conductor is realized by an electrical conductor 6 within the inner rail element 52, and the outer electrical conductor by a metallic coating 25 or a metallic foil on the outer rail element 5i.
[0121] The associated connector 3 has, along its longitudinal axis Ls, a contact element 12 serving as an inner conductor contact element 12i, which contacts the electrical conductor 6 of the rail 5, serving as an inner conductor, via an end contact at the first axial end region 15. The associated connector 3 also has a further contact element 12 serving as an outer conductor contact element 122. The outer conductor contact element 122 surrounds the contact carrier 11 in a fork-like manner towards the first axial end region 15. As shown in Figures 6B and 6C, a spring tab 26 for electrical and mechanical contact of the metallic coating 25 on the outer rail element 5i is formed on each of the two fork-shaped projections of the first axial end region 15 of the outer conductor contact element 122. The outer conductor contact element 122 surrounds the inner conductor contact element 12i quasi-coaxially in the second axial end region 16.In addition, several contact pins for electrical and mechanical contacting with an associated electrical contact or with an electrical conductor of the electrical assembly 17 are formed on the second axial end region 16 of the outer conductor contact element 122 (for example, four contact pins in Figs. 6A to 6D).
[0122] Figure 6D shows the circular path of the magnetic circuit 22, consisting of a connector-side segment 22i and a rail-side segment 222 for guiding the magnetic flux. This flux encircles the electrical conductor 6 of the rail 5 and also runs circularly within the metallic coating 25 of the outer rail element 5i. The magnetic flux guided in the magnetic circuit 22 is generated by both the inner and outer conductors of the electrical line 4.
[0123] In a fourth embodiment of the electrical conductor 4 according to Fig. 7, the rail 5 is formed in one piece and made solely of a soft magnetic plastic. The cross-sectional profile of the one-piece rail 5 in Fig. 7 corresponds essentially to the cross-sectional profile of the two-piece rail 5 consisting of the inner rail element 5i and the outer rail element 52 according to Fig. 4A.
[0124] In a fifth embodiment of a connector 3 according to Fig. 8, contact carrier areas 27 of the contact carrier 11, which extend in the direction of the transverse axis Qs of the connector 3 adjacent to a centrally formed contact carrier area or connection area 28 of the contact carrier 11 in which the contact elements 12 are arranged, are made of a soft magnetic plastic. The centrally formed connection area 28 of the contact carrier 11 can be made of a non-soft magnetic plastic. The two externally formed contact carrier areas 27 and the centrally formed connection area 28 of the contact carrier 11 can be joined by a material bond, for example by adhesive bonding, or manufactured using a multi-component plastic technology (2K technology).Alternatively, the externally formed contact carrier areas 27 of the contact carrier 11 made of a soft magnetic plastic can also be formed as separate additional elements 29 of the connector 3 made of a soft magnetic plastic, which can be connected to the central connection area 28 of the contact carrier 11 by means of bonding or by means of a snap-fit or clip connection.
[0125] In a sixth embodiment of the invention according to Figures 9A and 9B, the magnetic circuit 22 is formed solely within the electrical conductor 4. Thus, the use of a soft magnetic plastic in the contact carrier 11 of the connector 3 is only optional. The rail 5 again comprises an inner rail element 52 made of the soft magnetic plastic and an outer rail element 5i (where the rail 5 can also be formed in one piece in this embodiment). As before, the inner rail element 52 forms a rail-side segment 22i of the magnetic circuit 22. To complete the magnetic circuit 22, the following is provided in the embodiment shown in Figures 9A and 9B:
[0126] In the embodiment shown in Figures 9A and 9B, an additional component 30 made of soft magnetic plastic is provided, which can be inserted into the recess 7 of the rail 5 adjacent to the electrical connector 3 or its connection area 28 – that is, beyond the contact elements 12. The additional component 30, shown in a perspective view in Figure 9B, can, for example, be selected by a technician from a quantity of additional components 30 of different lengths or cut to the desired length from a stock, in order to continue to allow flexible positioning of the electrical connectors 3 in the electrical line 4 or in the rail 5. The additional component 30 can provide the missing segment of the magnetic circuit 22.
[0127] As an alternative to an additional component 30, the magnetic circuit can also be formed solely by the inner rail element 52 and / or by the outer rail element 5i and / or by a corresponding one-piece rail 5. In these variants, discrete slots for the individual electrical connectors 3 can be formed in the recess 7. To avoid creating interference points, this variant of the invention may also require inserting an electrical connector 3 into each of the aforementioned discrete slots. Therefore, this variant of the invention is generally less preferred due to its lack of flexibility.
[0128] Regarding the further technical features of the data transmission system 1 in Figs. 9A and 9B, reference is made by way of example to the description of the technical features of the data transmission system 1 in Figs. 3A to 3D.
[0129] Although the present invention has been fully described above with reference to preferred embodiments, it is not limited thereto, but can be modified in many different ways.