EP2466697B1 - Data cable connection module and method for producing same on a cable - Google Patents

Description

The invention relates to a data cable connection module and a method for its assembly on a cable.

From the prior art, for example DE102004004229B4 , is known to attach a contact module to a multi-core cable. This data cable connection module on the assembled multi-core cable with a cable plug and a socket element is a major step forward compared to the previous, time-consuming new installation when changing the socket / plug, but it can be improved:
The known data cable connection module is quite long because it essentially has three subassemblies, namely a fixing element in which the individual cable cores are fixed in a spatially defined manner and can be contacted; a sleeve element, in which the isolated cores are shielded; and a replaceable contact module with housing and a standardized plug face.

The known contact module can be connected to its fixing element - only detachable using special tools - and has on the one hand connection contacts for the fixing element contacts and on the other hand a common connection component, for example an RJ45 socket, and an intermediate sleeve element. In the known data cable connection module, the individual cable cores are shielded from one another mainly by metal plates which are accommodated in a star-like manner in the sleeve element in an insulator, each of which is intended to shield wire pairs from other wire pairs and are part of the contact module. A solid outer shield is missing and the connection of the inner shielding star to the fixing element - thus the known data cable connection module tends to leak radiation.

Therefore, only Cat.7 can be achieved with the known data cable connection module and it cannot be used in narrower cable channels. The non-continuous shielding is only suitable for transmission speeds up to approx. 600 MHz, since radiation leaks occur and sufficient return loss for frequencies of 1 GHz and an increase in the limit value to 10 dB is not possible. Thus, the known data cable connection module can only meet Cat.6 _A (ISO / IEC 11801), which corresponds to a conventional RJ45 connector.

Finally, the known data cable connection module can only be separated from the sleeve unit using a special tool in order to be able to attach a new contact module, which also results in limited interchangeability (approx. 10 connections). Automatic assembly is difficult or impossible with the known data cable connection module. The known "data cable connection module" can thus be improved.

Because the wire contact is circular, contact cannot be made automatically (access over 360 ° is very difficult).

Furthermore disclosed US 2006/246780 A1 a data cable connection module.

It is the task of the prior art to avoid the disadvantages of the prior art.

The object is achieved according to the invention by a data cable connection module with the features of patent claim 1 and a method for automatic assembly of the data cable connection module according to claim 5. Advantageous further developments result from the dependent claims.

The data cable connection module according to the invention, as defined in claim 1, enables surprisingly simple automatic production of the same and simple handling - for example when exchanging connection modules.

In general, the fixing element is often referred to as a "cable plug", while the contact module is used as a socket element, which can be replaced by plugging, depending on the requirements of the network.

The data cable connection module according to the invention has better technical properties and a considerably simplified manufacture and handling compared to known modules of this type.

The use of the advantageous new data cable connection modules is also possible in networks with 500 ≥ 1600 MHz, even up to over 3000 MHz (Cat.7 _A ) and the new data cable connection module corresponds to the provision of a suitable contact module - e.g. TERA - Cat.7 _A. The connector face can then be designed accordingly (eg TERA or GG45).

In an advantageous embodiment, the fixing element and the contact module in the data cable connection module according to the invention are polygonal and have latching elements for a snap closure which can be opened reversibly, for example by means of a screwdriver, together with corresponding latching elements on the contact module.

One or more devices for centering and / or for correct alignment of the fixing element can be provided both on the fixing element and on the contact module during insertion into the rear section of the contact module. The front connector face of the exchangeable contact module preferably corresponds to the standards ISO / EC 11801 or EN 50173.

However, the invention also includes an advantageous method for assembling such a data cable connection module according to claim 5, which can preferably be carried out automatically in automatic assembly machines.

In particular, due to the simple design of the data cable connection module with few individual parts, automatic assembly is easily possible.

The fixing element can be attached to a cable end in a simple manner. For this purpose, the cable is first stripped in the end area and inserted into the fixing element housing so that the exposed wire ends - here eight wires - protrude into the fixing element and the cable jacket ends in the strain relief of the fixing element. The exposed wire ends are arranged in pairs around a shield cross with an outer shield - on the wire ends - from the opposite side of the cable - insulating wire support blocks - also known as pushers - with openings running perpendicular to the wire cutouts for curved insulation displacement contacts. The insulation displacement contacts, on the other hand, are accommodated in insulation displacement contact receptacle blocks, which also have contact openings for module plug contacts. When the cutting contact receptacle blocks are installed, the wire insulation is cut through and conductive contact is established with the copper wires and the cutting contacts. This arrangement is fastened in a fixing element housing. An interchangeable contact module housing, which is designed, for example, with an RJ45 socket or another connection element, can now be attached to such a fixing element, which here has a latching device that can be opened with a screwdriver or the like.

The contact module can easily be produced by inserting curved sliding contacts, which have connection ends connected to at least one printed circuit board, into an insulation holder with subsequent attachment of module plug contacts for the fixing element on the printed circuit board and sliding on a module housing.

• Leichte Umrüstung von RJ45 auf Cat.7_A-Komponenten möglich durch bessere Schirmung im Fixierelement
• Einfachere automatische und händische Konfektionierung, da weniger Teile
• Herstellung ohne Schneidwerkzeuge
• Leicht ohne Spezialwerkzeug zu entriegeln, falls Auseinanderbau gewünscht;
• in engeren Kabelkanälen, als bisher möglich, einsetzbar, daher grösserer Einsatzbereich

Because the fixing element provides an arrangement of the cable cores to which different contact modules (“sockets”) can be plugged, a suitable connecting element that meets the requirements can be attached and removed in a simple manner without soldering or the like. In particular, when changing a category of a network from Cat6 to Cat7, an extremely simple conversion is possible without the cables having to be pulled or connected again. The fact that compared to the conventional contact modules available on the market DE102004004229B4 a complete component (the sleeve element used there) is saved, an advantageously shorter overall length can be achieved. In contrast to the known data cable connection module, which has a shield cross in the middle, which is not sufficiently far from the conductors, does not have a circumferential shield and therefore does not have sufficient return loss, it now has circumferential full shielding in the fixing element is present, which ends at the contacts of the fixing element, the unshielded area of the wires is much shorter than that DE 102004004229B4 and there is a significantly better return loss. The system is therefore open to higher-quality EC7 or Cat.7 _A connector and network systems. The design also makes it easy to mount and, if necessary, disassemble the plugs on the fixing elements without a special tool, and in a preferred embodiment, a simple tool with a blade is inserted and rotated in the locking device, thus releasing the lock between the contact module and fixing element becomes. The following advantages are achieved by the plug system according to the invention:

• Easy conversion from RJ45 to Cat.7 _A components possible thanks to better shielding in the fixing element
• Easier automatic and manual assembly because fewer parts
• Manufacture without cutting tools
• Easy to unlock without special tools if disassembly is required;
• Can be used in narrower cable ducts than was previously possible, hence a larger area of application

Furthermore, in the case of the data cable connection module according to the invention, with only a single defective frontal contact module or, if desired, for a different contact module, it is no longer necessary to replace or reinstall the complete wiring including the socket, but it is sufficient to quickly and easily remove and open the defective or undesired contact module from the fixing element put on a new contact module.

So when changing the configuration of the mating face - for example when a transition to a different socket or plug type is required - this can be done without the feared replacement of the complete, firmly connected cable contact module unit or cable socket unit be accomplished quickly and easily. An improved data cable connection module is thus provided which, if a single contact module is defective, does not require the expensive, tedious and time-consuming replacement of the entire, permanently connected cable contact module unit or cable socket unit and which is quick, simple and inexpensive to implement different types Mating face configurations - and so that the mating face can be easily adapted to different mating connectors.

• Fig. 1 eine schematische Explosionsansicht des erfindungsgemässen Datenkabelanschlussmoduls;
• Fig. 2 eine schematische Explosionsansicht einer Ausführungsform des Kontaktmoduls für Cat.6_A;
• Fig. 3 ein Detail miteinander in Eingriff zu bringender Bestandteile von Fixierelement und Kontaktmodul
• Fig.4 eine perspektivische Ansicht des zusammengebauten Datenkabelanschlussmoduls; und
• Fig.5 eine Seitenansicht des zusammengebauten Datenkabelanschlussmoduls der Fig.4 .

The invention is described in more detail below on the basis of exemplary embodiments and the accompanying drawing. It shows:

• Fig. 1 a schematic exploded view of the data cable connection module according to the invention;
• Fig. 2 a schematic exploded view of an embodiment of the contact module for Cat.6 _A ;
• Fig. 3 a detail of components of the fixing element and contact module to be brought into engagement with one another
• Figure 4 a perspective view of the assembled data cable connection module; and
• Figure 5 a side view of the assembled data cable connection module of the Figure 4 ,

How from Fig. 1 As can be seen, the data cable connection module according to the invention for positioning, separating and fixing the wires 1 comprises a fixing element 3. This is used for the fixed geometric arrangement of the wire ends for plug connections. The fixing element 3 is attached to the cable end to be provided with the data cable connection module and comprises a fixing element housing 4 with a cable inlet, transitions between wires and contact devices and corresponding shielding devices 5, which shield the wires against one another in pairs and also provide an outer shield to avoid electromagnetic interference.

To do this at in Fig.1 Embodiment shown, the star-like branched shielding devices 5 lateral shielding plates for the wires 1 and other electrical conductors (insulation displacement contacts) positioned in pairs in them in wire receiving blocks (pushers) (16). In contact with the wire receiving blocks there is an insulation displacement contact receiving block 18 for insulation displacement contacts 14. The insulation displacement terminals penetrate through a corresponding opening in the respective wire receiving block 16 and cut the wire insulation there by contacting the respective conductors. Outside the wire receiving blocks 16, the insulation displacement contacts 14 in insulation displacement contact receiving blocks 18 are provided with contact openings for plug elements 12 of pluggable modules. A fixing element housing 4 is arranged around this structure, which offers an outer shield and can have a cable strain relief and, if appropriate, also latching elements for contact modules 7 to be connected.

The fixing element 3 ends at the front with the insulation displacement contact receiving blocks 18 with contact openings into which the module plug contacts 12 can be inserted.

The fixing element 3 can be attached to the data cable in a reversible and irreversible manner. An irreversible attachment can take place, for example, by gluing, pouring, clamping or pressing the cable jacket with the fixing element 3.

A reversible and replaceable contact module 7-in which can be attached to the fixing element 3 Fig. 1 designed as a TERA connection module - has sliding contacts 10 in a plastic insulation holder 32, which have connection ends 6 to a contact printed circuit board 20. The connected / plugged-in - contact circuit board 20 connects the sliding contacts to module plug contacts 12. The module plug contacts 12 are partially accommodated in a shielding insulator block 31, which defines the geometrical arrangement thereof. The pin-like module plug contact ends, which protrude from the shielding insulator block 31, can be plugged together in an electrically conductive manner with the front ends of the insulation displacement contacts 14 in plug openings in the insulation displacement contact receiving block 18 of the fixing element 3 and thus connect the fixing element and contact module (see. Fig. 3 ).

The contact module housing 8 has in Fig. 1 at the front a socket / mating face 9 according to TERA with electrically conductive sliding contacts 10 and possibly a fastening spring 34.

In Fig. 2 another embodiment of the contact module 7 is shown as an RJ45 element. In the RJ45 embodiment, curved sliding contacts 10 are placed on a printed circuit board in such a way that they rest with it and a compensation printed circuit board make a connection and added a plastic insulation holder 32. The printed circuit board 20a is now inserted into a second printed circuit board 20, which connects the module plug contacts 12 of the contact module. The module plug contacts 12 are partially accommodated in a terminating insulator block 31, which stabilizes the contacts 12 during the plugging and closes the RJ45 contact module. The contact module housing 8, which may have a fastening spring 34 and a shield spring 33 for the plastic insulation holder 32, runs around this arrangement.

In the assembled state, the ends of the module plug contacts 12 of the exchangeable contact module housing 8 are in an electrically conductive connection with the insulation displacement contacts 14 in the insulation displacement contact receiving block 18. As a rule, the fixing element 3 is polygon, among other things, in order to achieve an easy positioning of the different plug / socket arrangement.

One or more devices for centering and / or for correct alignment of the fixing element 3 during the insertion of the contact module 7 can also be provided on the fixing element 3, for example in the form of guide lugs and corresponding guide grooves.

In the automated manufacture of the fixing element according to the invention, the cable jacket is first removed from the cable at its end and the wires 1 thus exposed are drawn into the fixing element housing 4. There, the wires 1 are drawn into guide blocks 16 which have insulation displacement contact guides, through which an insulation displacement contact 14 can be connected to the wire 1 at right angles to the course of the wire 1 by cutting the wire insulation. The insulation displacement contacts 14 connected in this way are now bent with their free ends and introduced into openings of insulation displacement contact receiving blocks 18, which are grouped around a shield cross 5 with an outer shield. The plug connection and connection of a contact module 7 can then take place through openings in the respective insulation displacement contact receiving block 3 that are accessible from the outside.

A contact module 7 can also be created automatically. With a contact module 7 according to TERA, as in Fig.1 and in detail also in Fig. 3 is shown first the contact wires for the sliding contacts 10 are correctly bent and placed in a plastic insulation holder 32 and then inserted together with them into the contact module housing 8. The rear ends 6 of the sliding contacts end on circuit boards 20. The module plug contacts 12 are located on the opposite surface of the printed circuit boards 20, partially accommodated in terminating insulator blocks 31. Like produce reversible cable. The data cable is thus equipped with the desired connection modules, making it easier to re-install if necessary.

RJ45 modules as in Fig. 2 shown can be made automatically in a similar manner. Sliding contacts 10 are bent around a carrier, in a plastic insulation holder 32, if applicable. also with a compensation circuit - inserted and connected to a circuit board 20a by application, which is inserted into another circuit board 20, which runs at right angles thereto. Printed circuit board 20 carries the module plug contacts 12, which are partially accommodated in a plastic insulation holder 32, as in the embodiment of the TERA plug.

As a result, both the contact modules and the fixing element can be automatically produced without any problems or cables can be assembled with the same, and a considerable amount of work for subsequent installation can be saved or the connection security can be increased.

Although the invention has been explained on the basis of preferred exemplary embodiments, it is obvious to the person skilled in the art that it is in no way restricted to the illustrated embodiments, but rather extends to the scope of the claims.

LIST OF REFERENCE NUMBERS

1

Vein

3

fixing

4

Fixierelementgehäuse

5

screen devices

6

End of sliding contacts 10

7

Contact module (plug or socket)

8th

exchangeable, front contact module housing

9

Mating face of the contact module

10

electrically conductive contact elements of 7

12

Module plug contacts from 7

13

Core cut-out in 16

14

IDC contact block of 3

16

Wire receiving block (pusher) of 3

18

Insulation displacement contact of 3

20

Contact PCB (s) of 3

20a

Contact circuit board of the RJ45 connector

31

Terminal isolator block from 7

32

Plastic insulation holder from RJ45 of 7

33

Shield spring from RJ45 of 7

34

Contact spring of the contact module housing 8 at TERA

Claims (6)

1. Data cable connection module, comprising:

   - a fixing element (3) for positioning and fixing the cores (1) of a multicore cable, which fixing element is fitted to one end of the cable, having:

   • core receiving blocks (16) with core guides (13) and connection openings for bent insulation-displacement contacts (14),

   • insulation-displacement contact receiving blocks (18) for holding the connected insulation-displacement contacts (14) having contact openings, wherein in each case one insulation-displacement contact receiving block (18) for the insulation-displacement contacts is in contact with the core receiving blocks (16), and wherein the core receiving blocks (16) have insulation-displacement contact guides through which, as viewed at a right angle in relation to the profile of the cores, the insulation-displacement contacts (14) are connected to the cores by cutting into the core insulation,

   • a central metal shielding star (5) having outer shielding elements which are arranged between/around the insulation-displacement contact receiving blocks (18) and which shielding star shields in each case two cores from other pairs of cores and is conductively connected to the fixing element housing (4);

   • a fixing element housing (4); and

   - an exchangeable contact module (7), which can be releasably connected to the fixing element (3), having a contact module metal housing (8),

   • an insulation holder (32), which is arranged in the contact module metal housing (8), for receiving bent sliding contacts (10) having connection ends (6) for connection to a printed circuit board (20);

   • at least one printed circuit board panel (20) between sliding contacts (10) and module plug-in contacts (12), which printed circuit board panel connects sliding contact ends (6) to module plug-in contacts (12) for the fixing element (3),

   • a front plug face (9) for external connectors in accordance with the requirements; and

   • a fixing element connection plug-in face with module plug-in contacts (12) which are guided in at least one terminal insulator block (31), wherein

   - the fixing element (3) and the contact module (7) are configured such that they can be brought into engagement so as to establish an electrical connection between module plug-in contacts (12) and the insulation-displacement contacts (14), so that the cable cores (1) of the fixing element (3) are electrically conductively connected to the sliding contacts (10) of the contact module (7), wherein the insulation-displacement contacts (14) are received in the insulation-displacement contact receiving blocks (18) which have the contact openings for the module plug-in contacts (12).
2. Data cable connection module according to Claim 1, characterized in that the fixing element (3) is polygonal and has latching elements for a reversibly openable snap-action closure together with corresponding latching elements on the contact module (7) .
3. Data cable connection module according to either of the preceding claims, characterized in that one or more devices for centring and/or for correctly orienting the fixing element (3) during plug-connection of the contact module to the fixing element are provided on the fixing element (3) and on the contact module (7).
4. Data cable connection module according to one of the preceding claims, characterized in that the plug-in face (9) of the contact module (7) meets connection standards selected from ISO/EC 11801 and EN 50173.
5. Method for manufacturing a data cable connection module according to one of the preceding claims, characterized by:

   - producing the fixing element, which is connected to a data cable, by:

   • removing the cable sheath so as to expose the insulated cores of a data cable,

   • inserting the insulated cores into core receiving blocks with insulation-displacement contact openings;

   • inserting bent ends of insulation-displacement contacts into the insulation-displacement contact openings of the core receiving blocks so as to sever the core insulation and make contact with the electrical conductors;

   • pushing insulation-displacement contact receptacles onto the free ends of the insulation-displacement contacts;

   • providing a shielding star having outer shielding elements between/around the insulation-displacement contact receptacles;

   • inserting the arrangement into a fixing element housing;

   - producing a contact module by:

   • presenting bent sliding contacts with connection ends and sliding-contact regions;

   • inserting said sliding contacts into an insulation holder;

   • connecting at least one printed circuit board to the connection ends of the sliding contacts;

   • connecting module plug-in contacts to the at least one printed circuit board so as to establish an electrical connection between the sliding contacts and the module plug-in contacts by way of the at least one printed circuit board;

   • inserting the module plug-in contacts into at least one terminal insulator block, and

   • inserting the structure into a contact module housing.
6. Method according to Claim 5, characterized in that it is carried out at least partially by automatic machines.

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