Differential Plug Connector Layout for Low-Capacitance Signal Transmission
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Solution Overview
Problem
Existing electrical plug connectors face challenges in transmitting high-frequency signals effectively due to capacitive influences from support shoulders in inner-conductor contact element pairs, which reduces their suitability for high-data-rate applications in the automotive industry, where reliability, compactness, and economic mass production are critical.
Innovation Solution
The design features inner-conductor contact elements with a single support shoulder and an asymmetrical configuration, allowing for reduced capacitance and improved signal transmission, along with an outer-conductor assembly for electromagnetic shielding and impedance control, enabling efficient high-frequency signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two oppositely situated support shoulders are used for centered pressing-in action, then mechanical reliability is improved, but capacitive influence increases reducing signal transmission quality
Solution Approach 1:
The patent applies asymmetry by providing only one support shoulder instead of two oppositely situated support shoulders. This single support shoulder is positioned at a specific location on the inner-conductor contact element to provide mechanical support during pressing-in while minimizing capacitive influence. The asymmetrical design reduces the capacitive effect that would otherwise degrade high-frequency signal transmission, while still ensuring centered pressing-in action through proper positioning of the single support shoulder.
2Reliability
If press-in pins are pressed with high pressing-in pressure into metal-plated recesses, then connection reliability is improved, but risk of cracks and fractures in electrical assembly increases
Solution Approach 1:
The patent applies beforehand cushioning by providing a support shoulder on the inner-conductor contact element that acts as a cushioning element during the pressing-in process. This support shoulder distributes the pressing-in force more evenly and prevents excessive localized stress that could cause cracks or fractures in the electrical assembly. The support shoulder ensures that the pressing-in action is centered and controlled, maintaining connection reliability while protecting the electrical assembly from damage.
3Volume of moving object
If compact design is implemented to save structural space and weight, then vehicle system efficiency is improved, but assembly complexity increases
Solution Approach 1:
The patent applies merging by integrating the support shoulder directly into the inner-conductor contact element structure. This integration combines multiple functions into a single component: the inner-conductor contact element provides both electrical connection and mechanical support during assembly. By merging the support function into the contact element itself, the design achieves compact dimensions while avoiding additional separate components that would increase assembly complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances the plug connector's ability to transmit high-frequency signals with reduced capacitance, supports economic mass production, and ensures reliable assembly, addressing the need for compact, high-performance connectors in the automotive industry.
Implementation Method 1
This causes cold welding, and a cohesive connection forms between the press-in pins and the recesses.
Implementation Method 2
along with an outer-conductor assembly for electromagnetic shielding and impedance control, enabling efficient high-frequency signal transmission.
Data Source
AI summary
An electrical plug connector, having an insulating part and an inner-conductor contact element pair for differential signal transmission. The inner-conductor contact element pair comprises first and second inner-conductor contact elements, which extend through the insulating part. The inner-conductor contact elements, proximate a first end of the insulating part, have a contact section for contacting an inner conductor of a corresponding counterpart plug connector and proximate a second end of the insulating part, have a press-in pin for pressing into a metal-plated recess of an electrical assembly. The inner-conductor contact elements each have one support shoulder via which a pressing-in force can be introduced for pressing the press-in pin into the metal-plated recess. The support shoulder is along the central axis of the inner-conductor contact element. The inner-conductor contact elements each have a support surface averted from the support shoulder to support the inner-conductor contact element in the insulating part.