Conductive Gap Fillers for Impedance Control in Electrical Connectors
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Solution Overview
Problem
Existing electrical connector systems face issues with signal loss and degradation due to cross-talk caused by electromagnetic coupling, and they struggle to maintain impedance control as the density and size of connectors increase to meet performance demands.
Innovation Solution
The introduction of conductive gap fillers with deflectable spring fingers between the receptacle and header connectors provides impedance control by spanning the gap between the connectors, ensuring optimal signal transmission and reducing the impact of air gaps on impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrical connectors are placed in close proximity to increase density, then throughput of the electrical system increases, but cross talk increases due to electromagnetic coupling
Solution Approach 1:
A dielectric material is introduced as an intermediary substance between adjacent electrical connectors to reduce electromagnetic coupling. The dielectric material acts as a mediator that blocks or reduces the electromagnetic fields from interacting, thereby reducing cross talk while allowing the connectors to remain in close proximity for high density and throughput.
2Volume of moving object
If connectors are reduced in size to increase density, then size of electrical connectors decreases, but impedance control becomes more difficult
Solution Approach 1:
The dielectric constant of the material between connectors is changed and optimized to compensate for the reduced size of connectors. By adjusting the dielectric parameter of the surrounding material, the impedance characteristics are maintained even as the physical dimensions of the connectors are reduced, enabling small size while preserving impedance control.
3Ease of operation
If air gap is present between mated connectors, then mechanical alignment is simplified, but impedance control is affected due to different dielectric constant
Solution Approach 1:
The dielectric material serves as a continuous intermediary that fills the air gap between mated connectors. This eliminates the discontinuity in dielectric constant that would otherwise occur at the air gap interface, maintaining consistent impedance control while allowing the connectors to be mechanically aligned without precision requirements for gap closure.
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 minimizes signal loss and degradation by maintaining controlled impedance, enhancing the electrical performance of the connector system even when air gaps are present, thereby improving the overall throughput and efficiency of the electrical system.
Implementation Method 1
The gap fillers provide impedance control for the header signal contacts along the gap
Implementation Method 2
The gap fillers include deflectable spring fingers
Data Source
AI summary
An electrical connector system includes a receptacle connector having a receptacle housing holding a plurality of receptacle signal contacts arranged in pairs carrying differential signals. The receptacle housing has a front face. The system includes a header connector coupled to the receptacle connector. The header connector includes a header housing holding a plurality of header signal contacts arranged in pairs carrying differential signals and mated with corresponding receptacle signal contacts. The header housing has a front face that opposes the front face of the receptacle housing when coupled thereto with a gap being defined between the front faces. Gap fillers are provided within the gap. The gap fillers are conductive and include deflectable spring fingers. The gap fillers provide impedance control for the header signal contacts along the gap.