Active HDMI Connector with Integrated Active Module
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Solution Overview
Problem
Standard HDMI cables experience significant signal attenuation when transmitting high-definition data over long or ultra-thin cables, failing to meet high data transfer rate standards due to signal loss, which is partially addressed by adding an active module chipset but requires complex assembly and increased length.
Innovation Solution
An integrated active HDMI connector design where the active module circuit board is partially enclosed within a connector shell, providing improved electromagnetic interference shielding and simplifying the manufacturing process by combining the active module and connector body into a single unit, reducing the overall length and requiring only a single soldering step between cable wires and contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an active module chipset is added to the connector pin assembly to address signal attenuation, then signal boosting and equalization are improved, but device complexity and assembly complexity increase
Solution Approach 1:
The active module circuit board is partially enclosed within the connector shell, merging the active module and connector body into a single integrated unit. This reduces assembly complexity by eliminating separate assembly steps while maintaining signal boosting and equalization functions through the integrated active chipset.
Solution Approach 2:
The active module circuit board is nested partially inside the connector shell, with the active chipset enclosed within the shell structure. This nesting arrangement integrates multiple functional components into a compact configuration, reducing overall device complexity while preserving signal transmission reliability.
2Reliability
If an active module chipset is added to the connector pin assembly to address signal attenuation, then signal boosting and equalization are improved, but the overall connector length increases
Solution Approach 1:
The active module circuit board is nested partially inside the connector shell rather than being entirely external, reducing the overall connector length from 23.3 mm to 18.3 mm. This nesting configuration maintains signal boosting functionality while achieving a more compact form factor.
Solution Approach 2:
The active module is repositioned from an entirely external configuration to a partially internal configuration within the connector shell, changing the spatial arrangement from one-dimensional external attachment to three-dimensional integrated placement, thereby reducing overall length.
3Ease of manufacture
If the active module is entirely exposed outside the connector shell, then assembly and manufacturing are simplified, but electromagnetic interference shielding is insufficient
Solution Approach 1:
The active chipset is nested within the connector shell structure, providing electromagnetic interference shielding through the metallic enclosure. This partial enclosure maintains ease of manufacture by keeping the active module accessible while protecting it from EMI during operation.
Solution Approach 2:
The connector shell, which provides structural support and connection functions, is also utilized as an electromagnetic shield by enclosing the active chipset. This converts the shell from a simple mechanical component to a dual-function element that simultaneously provides structural integrity and EMI protection.
4Manufacturing precision
If multiple soldering steps are required for separate connector and active module assembly, then manufacturing precision can be maintained, but productivity decreases
Solution Approach 1:
The active module circuit board is integrated with the connector shell into a single assembly unit, reducing the number of soldering steps from multiple separate operations to a single soldering operation. This merging maintains manufacturing precision through integrated design while significantly improving productivity by eliminating repetitive assembly steps.
Solution Approach 2:
The active module and connector body are pre-integrated into a single unit during manufacturing, performing the assembly action in advance. This preliminary integration eliminates the need for multiple subsequent assembly and soldering steps during final product assembly, thereby improving manufacturing efficiency while maintaining precision.
Data Source
AI summary
An integrated design for an active HDMI connector is presented. The active HDMI connector comprises an active module circuit board, a connector pin assembly, connector pins, an insulation housing, and a metal connector shell. The connector shell partially encloses and partially exposes the active module. The connector pins each have a bent segment embedded in a molding assembly to fixate the pins within the molding assembly. The molding assembly defines a recessed slot for the active module. The active module has a cutout on a side of the module that is aligned with a tab on the connector shell. The tab is bent toward the inside of the connector shell to secure the active module inside the shell. The insulation housing includes pin separators that do not fully surround the connector pins.