Fine-Pitch CFPx Connector Alignment Using Mask and Ruler Assembly
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Solution Overview
Problem
Misalignment between the fine pitched connector pins of CFPx connectors and the pads of a module PCB leads to signal integrity issues and module malfunction due to back reflection and signal loss, which is critical for high-speed optical communication applications.
Innovation Solution
An apparatus, system, and method that includes a connector mask to hold the CFPx connector, a ruler for attachment to the PCB, and an adjustment mechanism to precisely align the connector pins with the PCB pads, ensuring high precision connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional connector attachment methods are used, then manufacturing speed is maintained, but alignment precision between connector pins and PCB pads deteriorates, causing signal integrity issues
Solution Approach 1:
The patent applies preliminary action by pre-positioning the connector mask and ruler assembly before the actual connector attachment. The mask is pre-aligned with the PCB pad locations using the ruler as a reference, and the connector is pre-positioned within the mask. This preliminary positioning ensures that when the connector is attached, it is already in the correct alignment, eliminating the need for post-attachment alignment adjustments and maintaining both precision and productivity.
Solution Approach 2:
The patent introduces intermediary elements (the connector mask and ruler) that mediate between the connector and the PCB. The mask serves as an intermediary carrier that holds the connector in the correct position, while the ruler serves as an intermediary reference tool that ensures the mask is aligned with the PCB pad locations. These intermediaries transfer the alignment information from the PCB to the connector, ensuring precise alignment without requiring direct manual adjustment.
2Manufacturing precision
If manual alignment methods are used, then alignment precision can be achieved, but manufacturing time increases significantly
Solution Approach 1:
The patent applies self-service by designing the mask-ruler-connector assembly to be self-aligning. The ruler has fixed reference marks that automatically align with the PCB pad locations when the mask is positioned on the PCB. The connector within the mask is held in a fixed position relative to the mask, so the entire assembly self-aligns without requiring manual measurement or adjustment. This eliminates time-consuming manual alignment operations while maintaining precision.
Solution Approach 2:
The alignment information and geometric relationships are pre-encoded into the mask and ruler during their design and manufacturing phases. The ruler's reference marks are pre-positioned to match the PCB pad layout, and the mask's connector positioning features are pre-configured to achieve the correct pin-to-pad alignment. This preliminary encoding of alignment data allows rapid, automated attachment without time-consuming manual alignment operations.
3Reliability
If high speed signal transmission is required, then connector pin alignment precision must be high, but this increases the difficulty of manufacturing and assembly
Solution Approach 1:
The mask and ruler serve as intermediary alignment tools that simplify the manufacturing process. Instead of requiring direct, difficult alignment of the connector pins with the PCB pads (which would be extremely challenging for fine-pitched connectors), the mask-ruler assembly mediates the alignment process. The ruler provides easy-to-use reference marks on the PCB, and the mask translates these references into precise connector positioning, making the assembly process much easier while ensuring the high alignment precision needed for signal integrity.
Solution Approach 2:
The patent segments the alignment function into separate components: the ruler handles the reference establishment on the PCB, the mask handles the connector positioning, and the connector handles the signal transmission. This segmentation allows each component to be optimized independently - the ruler can be made with large, easy-to-see reference marks, the mask can be precisely manufactured with fixed connector positioning, and the connector can focus on signal performance. The segmented approach makes the overall system easier to manufacture and assemble while maintaining the precision needed for high-speed signals.
Data Source
AI summary
An apparatus, system and method capable of providing a high precision connection between a plurality of pins of a C form factor pluggable (CFP) and a connection pad of a printed circuit board (PCB). The apparatus, system and method include: a connector mask suitable to receive therein a body of the CFP; a ruler suitable to receive therein the connector mask, and sized and shaped for direct physical associated with the PCB about the connection pad; and an adjustment mechanism at least partially passing through the ruler for contacting at least the connector mask and capable of adjusting the position of the pins in relation to the connection pad.