Multi-core Cable Connector with Integrated Filter Carrier
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Solution Overview
Problem
Existing electrical connectors for multi-core cables face challenges in managing space requirements due to the need for signal processing components, leading to increased space needs and inefficiencies in signal transmission.
Innovation Solution
An electrical connector design that incorporates a carrier body with a passive electrical component, such as a filter element, which connects cable-side and output-side contact elements in parallel, reducing space requirements by integrating the component between the cable and output contacts and using a casting compound to fill the interior space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If signal processing components are added to the electrical connector, then signal transmission quality is improved, but space requirements increase
Solution Approach 1:
The patent combines the signal processing function (filter element) with the mechanical support structure (carrier body) into a single integrated assembly. The filter element is mounted on the carrier body, which provides both structural support and electrical connection pathways, eliminating the need for separate mounting structures and reducing overall connector volume.
Solution Approach 2:
The patent implements a nested arrangement where the carrier body with the filter element is positioned within the connector housing, and the entire assembly is surrounded by the outer conductor. This nested structure maximizes space utilization by placing components concentrically along the cable axis, reducing the radial footprint of the connector.
2Adaptability or versatility
If multiple electrical components are integrated into the connector, then functionality is improved, but device complexity increases
Solution Approach 1:
The carrier body serves multiple functions simultaneously: it provides mechanical support for the filter element, establishes electrical connection pathways between cable-side and output-side contacts, and positions the filter element within the connector housing. This multi-functionality reduces the number of separate components needed, simplifying the overall device structure despite enhanced functionality.
3Object-affected harmful factors
If the connector interior space is filled with casting compound, then electromagnetic compatibility is improved, but manufacturing complexity increases
Solution Approach 1:
The casting compound changes the physical and electromagnetic parameters of the connector interior by providing a homogeneous dielectric material that fills voids and provides electromagnetic shielding. This single material addition simultaneously achieves multiple goals: improving EMC, providing mechanical support, and simplifying assembly of other components.
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 design effectively reduces space requirements while improving signal transmission by integrating passive electrical components, specifically filtering out common-mode interference, and enhancing the structural integrity and electromagnetic compatibility of the connector.
Implementation Method 1
The passive electrical component can be embodied in particular as a filter element, e.g. as a common mode filter ('Common Mode Choke'/CMC). It can also have an electrically insulating housing.
Implementation Method 2
And the interior space enclosed by the outer conductor can be filled with a casting compound.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
The invention relates to an electrical connector for a multi-core electrical cable, comprising at least two cable-side electrical contact elements (31, 32) with associated connection points (33, 34) to which a core (11, 12) of the electrical cable (1) is to be connected, and at least two output-side electrical contact elements (71, 72), each of which has an electrical plug element (73, 74) projecting from it, via which an electrical connection with a mating plug can be established. A carrier body (4) is arranged between the cable-side contact elements (31, 32) and the output-side contact elements (71, 72), which carries an electrical component (5) via which the at least two cable-side and the at least two output-side contact elements (31, 32; 71, 72) are electrically connected to each other.The carrier body (4) has a planar carrier area (40) which extends between a first connection section (41) and a second connection section (42) and which is directed transversely to the axial direction (a) of the connector.