Hybrid Plug Connector Layout for High-Speed Optical Data Links
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Solution Overview
Problem
Existing plug connectors for automotive applications face challenges in transmitting high data rates due to limited bandwidth, signal interference, and mechanical robustness, especially when combining optical and electrical signals, which are unsuitable for the cost-sensitive automobile market.
Innovation Solution
A plug connector design that integrates optical and electrical signal paths, using a contact support with aligned lens and locking mechanisms to ensure precise alignment and secure fastening, allowing for high data rates while maintaining mechanical integrity and compatibility with existing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional HSD plug connectors with copper line pairs are used, then electrical signal transmission is achieved, but the data rate is limited to approximately 3 Gb/s due to restricted transmission bandwidth
Solution Approach 1:
The patent combines optical signal transmission and electrical signal transmission into a single plug connector housing. The optical conductor (fiber optic) is integrated alongside electrical conductors (copper wires) within the same connector body, allowing simultaneous transmission of high-speed data and power/control signals through a unified interface.
Solution Approach 2:
The patent replaces the electrical signal transmission medium (copper conductors) with an optical transmission medium (fiber optic conductor) for the high-speed data path. This substitution enables significantly higher data rates by utilizing light instead of electrical signals, overcoming the bandwidth limitations of conventional copper-based HSD connectors.
2Speed
If multiple copper line pairs are used to increase data rate, then higher data rates can be transmitted, but the device complexity and installation space requirements increase significantly
Solution Approach 1:
The patent replaces multiple copper line pairs with a single optical conductor for high-speed data transmission. This substitution dramatically reduces the number of conductors required, simplifying the connector design and reducing installation complexity while achieving higher data rates.
Solution Approach 2:
The patent transitions from electrical signal transmission to optical signal transmission, representing a dimensional change in the transmission medium. This allows data to be transmitted through light waves rather than electrical currents, enabling higher bandwidth utilization without proportionally increasing the number of physical conductors.
3Device complexity
If optical and electrical signals are combined in one multiway cable, then cabling requirements and installation space are reduced, but precise alignment of optical components is required to maintain signal integrity
Solution Approach 1:
The patent nests the optical conductor and electrical conductors within a single connector housing structure. The optical fiber is positioned centrally or in a specific arrangement alongside the electrical conductors, with both types of conductors integrated into a unified connector assembly that simplifies installation while maintaining precise optical alignment.
Solution Approach 2:
The patent incorporates preliminary alignment features directly into the connector housing, such as positioning ribs, guide structures, or pre-aligned ferrules that ensure correct optical component alignment during the assembly process. This preliminary structuring of alignment features eliminates the need for complex post-assembly alignment procedures.
4Length of stationary object
If high data rates are transmitted over long line lengths, then sensor data can be transmitted from remote sensors to ECU, but signal impairments such as reflections and crosstalk increase
Solution Approach 1:
The patent replaces electrical signal transmission with optical signal transmission for long-distance data communication. Optical fibers inherently provide better signal integrity over long distances compared to copper conductors, as light signals are less susceptible to electromagnetic interference, signal reflections, and crosstalk that plague electrical transmission over extended line lengths.
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
Enables high data transmission rates exceeding 1 Gb/s with reduced signal loss and mechanical robustness, compatible with existing plug systems, and cost-effective without requiring extensive re-development.
Implementation Method 1
at least one lens fastening region, which is formed in the contact support and is configured to receive, in an aligned manner, a lens member, which is connectable to the line, for transmitting the optical signals
Data Source
AI summary
A plug connector, which can be fastened to a line, for transmitting optical and electrical signals, includes a contact support, two contact fastening regions, a lens fastening region and a locking member. The contact fastening regions are formed in the contact support and are each configured to receive an electrical contact, which is connectable to the line, for transmitting the electrical signals. The lens fastening region is formed in the contact support and is configured to receive, in an aligned manner, a lens member, which is connectable to the line, for transmitting the optical signals. The locking member is lockable to the contact support, and the line is fastenable to the plug connector using the locking member in a locked state.