Plug Connector Spring Element for Automotive EMC Integration
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Solution Overview
Problem
Existing Ethernet systems in automotive applications face challenges with electromagnetic compatibility (EMC) due to the use of unshielded twisted pair (UTP) cabling, particularly when sensitive links are integrated with wireless systems like cameras and antennas, and fully shielded systems are costly and increase component variance.
Innovation Solution
A plug connector system that combines shielded and unshielded cables using a resilient spring element with contacting portions to interconnect the shielding elements of sockets and cable heads, allowing for efficient deployment of both types of cables and ensuring sufficient EMC without increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fully shielded connector system is used instead of an unshielded system, then electromagnetic compatibility (EMC) performance is improved, but component variance increases and costs increase
Solution Approach 1:
The socket is designed with a universal structure that can accommodate both shielded and unshielded plug connectors. The socket includes a contact element and a housing that can receive either a shielded plug connector (with shielding connected to the contact element) or an unshielded plug connector (where the contact element serves as the ground reference). This multi-functionality allows the same socket to support different cable types without increasing component variance.
Solution Approach 2:
The invention provides an economical solution by allowing the use of standard unshielded sockets for most applications, with the option to use shielded plug connectors only where EMC performance is critical. This selective approach avoids the cost of deploying fully shielded systems throughout, while still providing enhanced EMC protection where needed.
2Object-affected harmful factors
If a fully shielded system is used for all Ethernet links, then EMC performance is improved, but costs increase
Solution Approach 1:
The invention applies shielding locally only where needed rather than universally. The socket design allows selective deployment of shielded plug connectors in locations with sensitive equipment (such as wireless systems in close proximity) while using standard unshielded connectors in other locations. This local quality approach optimizes EMC performance for critical links while controlling overall system costs.
3Ease of manufacture
If unshielded twisted pair (UTP) cabling is used, then cost is reduced, but electromagnetic compatibility (EMC) performance is limited
Solution Approach 1:
The shielded plug connector acts as an intermediary between the unshielded UTP cable and the socket. When a shielded plug connector is used with a UTP cable, the shielding in the plug connector provides an additional layer of electromagnetic protection at the connection point, thereby improving EMC performance while still allowing the use of cost-effective unshielded cabling for the majority of the cable run.
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
The plug connector system enhances EMC by allowing the use of existing sockets for both shielded and unshielded cables, enabling economic and flexible integration of shielded cables into unshielded systems, thereby improving electromagnetic compatibility without the need for costly fully shielded systems.
Implementation Method 1
a spring element made of a resilient material for electrically connecting the cable head and the socket
Data Source
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AI summary
The present invention relates to a plug connector (100) for accommodating a cable head (130) and for being inserted into a socket (160). The plug connector (100) can be used for economically and feasibly integrating shielded cables into unshielded data communication systems, for example for sensitive links in automotive applications where a high electromagnetic compatibility (EMC) is required. The plug connector comprises a plug connector frame (110) and a connection member for electrically conductively connecting the shielding elements of the socket and the cable head (130). Advantageously, the connection member is a spring element (120) made of a resilient material having two contacting portions for electrically conductively contacting shielding elements of the cable head (130) and the socket (160). A method for manufacturing a plug connector is also provided.