Combo Connector Terminal Layout for Dense Signal-Power Integration
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Solution Overview
Problem
Existing connectors struggle to provide reliable and compact integration of both signal and power connections for electronic components, particularly in harsh environments like automobiles or washing machines, while maintaining efficient cable density and reducing crosstalk.
Innovation Solution
The design of a combo connector with specific terminal arrangements and housing features that allow for signal and power terminals to be positioned in rows with power terminals being longer in a transverse direction, using opposing beams and polarization features to ensure reliable connections and prevent misinsertion, while allowing for dense packing and shock resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If signal and power terminals are integrated in the same connector housing, then cable density and space efficiency are improved, but terminal arrangement complexity and manufacturing difficulty increase
Solution Approach 1:
The connector housing is segmented into distinct regions: a first housing region for signal terminals and a second housing region for power terminals. This spatial segmentation allows independent optimization of each terminal type while maintaining compact integration, resolving the contradiction between compactness and arrangement complexity.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement within the housing, positioning signal and power terminals at different locations and orientations. The first and second housing regions are arranged to optimize space utilization, transforming a two-dimensional layout problem into a three-dimensional solution that reduces footprint while simplifying terminal management.
2Reliability
If power terminals are made longer in transverse direction for better power connection, then connection reliability is improved, but connector width and cable density increase
Solution Approach 1:
The patent applies different terminal length characteristics to different functional regions: power terminals in the second housing region are optimized with longer transverse dimensions for reliable power connection, while signal terminals in the first housing region maintain appropriate lengths for their specific functions. This local optimization allows power terminals to achieve high reliability without forcing the entire connector to increase in width.
3Area of stationary object
If multiple rows of terminals are packed densely for high cable density, then space efficiency is improved, but crosstalk between adjacent terminals increases
Solution Approach 1:
By segmenting the housing into separate first and second regions for signal and power terminals, the patent creates natural isolation zones that reduce electromagnetic interference and crosstalk. This segmentation allows dense packing within each region while maintaining adequate spacing between different terminal types, thus achieving high cable density without excessive crosstalk.
4Reliability
If polarization features and opposing beams are added for misinsertion prevention, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates asymmetric polarization features and opposing beams that provide mechanical prevention of misinsertion. These features are integrated into the terminal structures themselves, using simple geometric asymmetries that are easy to manufacture through standard molding or forming processes, thus achieving high reliability without significantly increasing manufacturing complexity.
Data Source
AI summary
A connector configured to provide signal and power connections reliably and economically in a compact space. The connector may include terminals each comprising a mating portion and a mounting portion opposite the mating portion. The terminals may be arranged with multiple rows of signal terminals and power terminals aligned in one row and on opposite sides of the signal rows. The mounting portions of the terminals may be configured to receive cables in some embodiments, and mount to a board in some other embodiments.