Cruciform Plug Connector for High-Frequency Differential Signals
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Solution Overview
Problem
Existing plug-in connectors for differential signal transmission are inadequate for high-frequency signals and do not provide optimal insulation and alignment for multiple twin-axial cable connections, especially in decentralized network technologies like Ethernet.
Innovation Solution
A cruciform plug-in connector with a contact carrier made from insulating material, featuring accepting grooves for axially-aligned electric contacts, surrounded by an insulating round body with a metallic housing, ensuring continuous insulation and precise alignment for circuit board assembly, and optionally embedded in a conductive sheath or non-conductive housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug-in connectors are used for differential signal transmission, then basic connectivity is achieved, but high-frequency signal transmission quality deteriorates due to insufficient insulation and alignment
Solution Approach 1:
The connector is divided into distinct functional segments: a cruciform shielding structure with four arms, four separate insulating chambers, and multiple contact pairs. Each segment performs a specific function (shielding, insulation, contact), allowing optimization of each part for high-frequency signals while maintaining overall connectivity.
Solution Approach 2:
The patent employs nested structures where insulating chambers are positioned within the cruciform shielding structure, contacts are inserted into the insulating chambers, and the entire assembly is housed within a connector housing. This nested arrangement provides multiple layers of protection and alignment for high-frequency signals.
2Reliability
If multiple twin-axial cable connections are made with conventional connectors, then connectivity is achieved, but signal insulation deteriorates leading to interference
Solution Approach 1:
Each of the four insulating chambers is specifically designed to house a pair of contacts for a single twin-axial connection. This localized insulation ensures that signals in adjacent chambers remain electrically isolated, preventing interference while maintaining simple individual chamber structures.
Solution Approach 2:
The cruciform shielding structure uses asymmetric positioning of the four insulating chambers relative to each other, with each chamber oriented to accommodate specific cable orientations. This asymmetric arrangement optimizes insulation between adjacent connections while simplifying the overall shielding geometry.
3Manufacturing precision
If precise alignment is required for circuit board assembly, then connection accuracy improves, but manufacturing complexity increases
Solution Approach 1:
The contact pairs are pre-positioned within the insulating chambers during connector manufacturing, and the insulating chambers are pre-aligned within the cruciform shielding structure. This preliminary positioning ensures that when the connector is assembled to the circuit board, the contacts are already in their correct final positions, achieving precise alignment without complex assembly procedures.
Solution Approach 2:
The patent combines multiple alignment functions into a single integrated structure: the cruciform shielding structure serves as both the mechanical framework and the alignment reference for the insulating chambers, which in turn provide alignment for the contact pairs. This merging of functions reduces the number of separate alignment operations required during manufacturing.
Data Source
AI summary
A round plug-in connector has a connection side configured for contacting circuit boards. For transmitting several independent, differential signals, the plug-in connector includes electric contacts arranged in pairs, with each of four signal pairs being insulated from each other by a cruciform structure, and being arranged inside an electrically non-conductive round body surrounding the cruciform structure. An electrically conductive screen cross is surrounded by a cruciform contact carrier with accepting grooves in diagonally embodied internal edges for holding the electric contacts. The round body is pushed over the cruciform arrangement, and is surrounded by an electrically conductive housing. Connection ends of the electric contacts that are intended to be aligned precisely on a circuit board, via a positioning aid, are attached to the round body. The positioning aid includes respective bore holes for the connection ends of the electric contacts, which coincide with soldered bore holes on the circuit board.