Twisted Wire Connector Spreader for Impedance Control
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Solution Overview
Problem
In rail-bound trains, connectors for twisted pair wires face issues with varying contact impedance and crosstalk due to the interruption of the twisted structure during termination, leading to bandwidth degradation and interference, especially in harsh environments and automatic coupling scenarios.
Innovation Solution
A connector with a spreader having contact pins embedded in dielectric material, which geometrically spreads the twisted wires for consistent contact impedance and is separable into parts for easy maintenance, combined with a sleeve for shielding and mechanical stability, ensuring constant impedance and efficient signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the twisted pair is split apart and distributed to individual connectors, then the connection can be made to terminal blocks, but the immunity against interference deteriorates and crosstalk increases
Solution Approach 1:
The connector is divided into a first part and a second part that can be separated. The twisted pair wires are distributed to individual connectors in the first part, while the shield is connected to the second part. This segmentation allows the connector to be disconnected into two pieces, enabling easy connection to terminal blocks while maintaining the twisted structure's integrity for interference immunity.
2Ease of manufacture
If the twisted structure is interrupted near the joint/termination, then the wires can be distributed to individual connectors, but the immunity against interference deteriorates
Solution Approach 1:
The connector is segmented into two separable parts: the first part handles wire distribution to individual connectors, while the second part maintains shield connection. This allows wire distribution without completely interrupting the twisted structure, preserving interference immunity while enabling manufacturing flexibility.
3Object-affected harmful factors
If a connector with conducting housing is used to connect the shield, then the shield can be connected, but the wires are not anchored and contact impedance varies
Solution Approach 1:
The connector is divided into two parts where the first part contains contact elements for wire distribution and the second part provides anchoring for the wires. This segmentation allows the shield to be connected while also providing a stable anchor point for the wires, ensuring consistent contact impedance across different connectors.
Solution Approach 2:
The connector acts as an intermediary between the twisted pair wires and the terminal block. It provides a stable mounting structure that anchors the wires and maintains their position, ensuring consistent electrical contact and impedance while allowing the shield to be properly connected.
4Reliability
If the connector is made robust for secure connection, then the connection reliability improves, but the terminal block becomes dimensionally large
Solution Approach 1:
The connector is segmented into two separable parts, allowing each part to be optimized for its specific function. The first part handles wire distribution with appropriate robustness, while the second part provides shield connection and anchoring. This segmentation enables a more compact overall design compared to a single large robust connector.
Data Source
Figure 1a~1b
Figure 2~3g
AI summary
A connector for termination of at least two incoming and pairwise twisted wires is shown comprising a spreader (5) connectable to a cable terminator (4), the spreader having contact pins (19) embedded in a dielectric material, the contact pins extending through the spreader and in at least a part of its extension having a radial direction. The spreader is further separable into at least two parts, the parts comprises paths arranged for the contact pins.