Backplane Connector Pin Header Air Dielectric Isolation
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Solution Overview
Problem
Existing electrical connectors face challenges in reducing cross talk between signal contacts due to overlapping electrical fields, which can compromise signal integrity, especially in high-speed electronic communication systems, and current solutions like metallic shields or air gaps either increase size, complexity, or compromise structural integrity.
Innovation Solution
The use of an air dielectric medium to isolate differential signal pairs in a pin header connector with a one-piece molded plastic housing, incorporating air passageways and partial core-outs to enhance electrical isolation without affecting structural integrity, allowing for uniform contact spacing and economical manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic shields are positioned between adjacent signal contacts to reduce cross talk, then signal integrity is improved, but connector size increases and contact density is limited
Solution Approach 1:
The patent removes the metallic shield component entirely and replaces it with an air gap created by positioning signal contacts at different heights. This extraction eliminates the space-consuming shield while maintaining electrical isolation through the air dielectric medium between differently positioned contacts.
Solution Approach 2:
The patent transitions from planar shielding to three-dimensional contact positioning. By stacking signal contacts at different vertical levels and using air gaps between these levels, the design utilizes the vertical dimension to achieve electrical isolation without increasing the horizontal footprint of the connector.
2Reliability
If metallic shields are used to block cross talk between signal contacts, then electrical isolation is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the metallic shield component, removing the associated manufacturing costs for shield fabrication, positioning fixtures, and assembly operations. The air gap isolation method uses the existing contact structures and spacing to achieve electrical isolation without additional expensive components.
Solution Approach 2:
The connector structure itself provides the electrical isolation function through its inherent geometry. The air gaps between differently positioned contacts create the necessary dielectric barrier without requiring separate shielding components, making the structure self-sufficient for both mechanical support and electrical isolation.
3Reliability
If air gaps are used between signal contacts to enhance electrical isolation, then cross talk is reduced, but structural integrity is compromised
Solution Approach 1:
The patent divides the connector into multiple stacked levels or layers, with each level containing signal contacts positioned at different heights. This segmentation creates natural air gaps between levels for electrical isolation while maintaining structural integrity through the distributed stacking arrangement that spreads mechanical loads across multiple contact points.
4Reliability
If multiple terminal supporting frames or wafers are used to create air gaps, then electrical isolation is improved, but device complexity increases
Solution Approach 1:
The patent combines the mechanical support function and the electrical isolation function into a single integrated structure. The stacked contact arrangement provides both structural support and creates the necessary air gaps for dielectric isolation, eliminating the need for separate terminal supporting frames or wafers that would add complexity.
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 solution effectively reduces cross talk in high-speed data transfer systems while maintaining the structural integrity and contact density of the connector, enabling reliable and efficient signal communication without the need for additional shielding or complex designs.
Implementation Method 1
differential signal pairs of electrical contacts that are effectively isolated by an air dielectric medium from signal contacts of adjacent or nearby differential signal pairs
Implementation Method 2
Cross talk occurs when one signal contact induces electrical interference in an adjacent contact due to the overlapping of electrical fields
Data Source
AI summary
A backplane electrical connector having a pin header that includes a one-piece housing supporting a plurality of columns of edge coupled differential signal pairs of contacts each separated by a ground contact. The pin header housing base is formed with a plurality of air passageways extending through the base, including an air passageway disposed between each signal contact in one column and an immediately adjacent signal contact in an adjacent column for electrically isolating the adjacent signal contacts from each other by an air dielectric medium. Core-outs which extend only partially through the housing base are provided between each signal contact and an adjacent ground contact in an adjacent column for further isolating differential signal pairs.