Board-to-Board Plug Connector Structure for High-Frequency Signal Stability
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Solution Overview
Problem
Existing board-to-board connectors face issues with structural strength and manufacturing complexity, particularly for heights exceeding 7 mm, leading to molding failures and increased process complexity.
Innovation Solution
A board-to-board plug connector design featuring a base portion with inner walls, a tongue portion, and a recessed portion, along with plug signal and power terminals, which includes a plug member to limit terminal movement and reduce exposure to air, enhancing high-frequency signal transmission and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connector height exceeds 7 mm, then the structural strength is insufficient leading to molding failure, but adding additional processes in mold manufacturing increases the manufacturing complexity
Solution Approach 1:
The connector is divided into a base portion and a plug member that can be separately molded and then assembled. The plug member fits into the base portion to form the complete connector structure. This segmentation allows each part to be molded independently with standard processes, avoiding the need for complex additional molding processes while achieving the required structural strength for heights exceeding 7 mm.
Solution Approach 2:
The plug member is nested within the base portion to form the complete connector assembly. The plug member fits into a cavity in the base portion, creating a compact integrated structure. This nesting approach allows the connector to achieve greater height and structural strength without requiring complex additional molding processes, as the components are assembled after standard molding.
2Reliability
If the terminals are exposed to air, then the high-frequency signal transmission performance deteriorates, but protecting the terminals increases manufacturing complexity
Solution Approach 1:
The base portion and plug member are designed to mate together such that the plug member covers and protects the terminals housed in the base portion. When assembled, the plug member forms a protective enclosure that limits terminal exposure to air, maintaining high-frequency signal transmission performance. This integration is achieved through standard molding and assembly processes without adding complex protective structures.
3Strength
If the plug member is made taller to accommodate terminals, then the structural strength improves, but the molding process becomes more complex
Solution Approach 1:
The connector structure is segmented into a base portion and a plug member. The plug member can be designed with the necessary height to accommodate terminals and provide structural strength, while being molded separately using standard molding processes. This segmentation avoids the need for complex single-piece molding processes while achieving the required structural strength.
Solution Approach 2:
The plug member is pre-formed with the required height and terminal accommodation features through standard molding processes before assembly. This preliminary formation allows the plug member to provide necessary structural strength without requiring complex additional processes during final assembly or molding.
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 design improves structural strength, maintains high-frequency signal performance, and reduces manufacturing complexity by limiting terminal movement and exposure, while allowing for enhanced heat dissipation and large current transmission.
Implementation Method 1
the flat contact section is interference-fitted with the exposed section
Implementation Method 2
the ribs are interference-fitted with the two inner walls of the base portion
Data Source
AI summary
A board-to-board plug connector includes a base portion, a plug member, and a plurality of plug signal terminals. Each of the plug signal terminals includes a fixed section, a flat contact section, and an extension section. Two ends of the fixed section respectively extend toward the flat contact section and the extension section. The base portion includes two inner walls, a tongue portion, a recessed portion, and a plurality of signal terminal grooves. The tongue portion is between the two inner walls, the signal terminal grooves are at two sides of the tongue portion and at the two inner walls, and the recessed portion is enclosed by one end of the tongue portion and the two inner walls. The plug member is arranged in the recessed portion, and the plug member contacts the extension sections of the plug signal terminals.