Cable Connector Assembly Impedance Matching via Wire Deformation

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Solution Overview

Problem

Existing cable connector systems face challenges in maintaining low loss interconnections, particularly for high-frequency signals, due to changes in geometry and impedance at the cable attachment interface, which can lead to signal integrity issues.

Innovation Solution

The solution involves deforming a portion of the cable wire to form a planar surface that matches the contact area of the connector, and using a metallurgical bond with selected materials to attach the wire to the connector edge, reducing the need for additional joining materials and minimizing impedance changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cable attachment methods are used, then the connection can be established, but impedance changes and signal integrity issues occur at the attachment interface

Engineering Contradiction:

Improvesignal integrityVSAvoidattachment interface geometry

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wire is deformed from its original cylindrical shape to a flattened configuration, changing its geometric parameters to match the contact area of the connector edge. This parameter change ensures impedance continuity and reduces signal integrity issues at the attachment interface.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Only the portion of the wire that contacts the connector edge is flattened, while the rest of the wire maintains its original cylindrical shape. This localized deformation achieves the desired impedance matching at the attachment interface without affecting the overall wire structure or requiring complex modifications throughout the entire assembly.

Inventive Principle:

Principle #3Local quality

2Strength

If additional joining materials are used to attach the wire, then the attachment can be strengthened, but impedance changes increase and signal integrity deteriorates

Engineering Contradiction:

Improveattachment strengthVSAvoidsignal integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The solution eliminates additional joining materials such as solder or adhesive from the attachment interface. By deforming the wire to match the connector edge geometry, the wire itself becomes the joining element, removing the need for separate joining materials that would otherwise disrupt the signal path and cause impedance changes.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The attachment function and the signal transmission function are merged into a single integrated structure. The deformed wire serves both as the mechanical connector and as the continuous signal path, eliminating the need for separate joining materials and ensuring impedance continuity throughout the attachment interface.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the wire is deformed to match the connector contact area, then impedance changes are reduced, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveimpedance consistencyVSAvoidwire deformation process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The wire is deformed to its final flattened shape before being attached to the connector edge. This preliminary deformation ensures that the wire is already in the correct geometric configuration for impedance matching, eliminating the need for complex deformation processes during the attachment operation itself and simplifying the overall manufacturing sequence.

Inventive Principle:

Principle #10Preliminary action

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 approach results in a robust and low-loss interconnection system with improved signal integrity by reducing impedance changes and maintaining a consistent attachment interface, suitable for high-frequency signals.

Implementation Method 1

deforming a portion of the cable wire to form a planar surface that matches the contact area of the connector

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

using a metallurgical bond with selected materials to attach the wire to the connector edge

Methodology Applied

Scientific EffectMetallurgical bond: Diffusion Welding

Data Source

PatentUS11437762B2High performance cable connector assembly

Publication Date: 2022.09.06 AMPHENOL CORP

AI summary

Connector assemblies that may be used to connect a cable to one or more contact tails of an electrical connector are disclosed. Some connector assemblies may include a wire extending from a cable and attached to an edge of a contact tail of a signal conductor. At least a portion of the wire may be flattened to form a planar surface that is attached to a corresponding planar surface of the edge of the contact tail. Moreover, some connector assemblies may include a wire extending from a cable that is attached to an edge of a contact tail via a metallurgical bond extending along at least a portion of an attachment interface between the wire and the contact tail.