Connector Contact Array Coplanar Solder Tails
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Solution Overview
Problem
Conventional communication connectors face challenges with non-coplanar solder tails, leading to misalignment and potential unsoldering issues during assembly, which can result in communication connector failure.
Innovation Solution
A receptacle connector assembly with a contact array that includes ground and signal contacts, where the signal mounting ends feature deflectable spring beams and solder tails that are deflected against the circuit board for secure soldering, and ground mounting ends are press-fit into plated vias, ensuring reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional connectors use bent 90° solder tails for mounting, then the connector can be surface mounted to the circuit board, but the solder tails become non-coplanar and mis-aligned, leading to soldering difficulties and potential failure
Solution Approach 1:
The contact structure is segmented into distinct functional zones: a mounting end with coplanar solder tails for precise circuit board attachment, a intermediate section for insulation and support, and a mating end for electrical connection. This segmentation allows each part to be optimized independently - the mounting end for precision soldering and the mating end for electrical performance.
Solution Approach 2:
The contact solder tails are pre-formed with coplanar geometry and proper alignment features before final assembly. The insulator is pre-positioned to hold the contacts in their correct spatial relationships, ensuring that when the connector is mounted to the circuit board, all solder tails are already aligned and ready for simultaneous soldering, eliminating misalignment issues.
2Ease of manufacture
If solder tails are bent 90° for mounting, then the connector can be attached to the circuit board, but the non-coplanar configuration causes some solder tails to be unsoldered, leading to connector failure
Solution Approach 1:
The contact array is segmented into individually supported contacts, each with its own insulator support structure. This allows each contact's solder tail to be independently positioned and soldered to its corresponding circuit board pad, ensuring that no solder tail is missed or misaligned, thereby improving reliability.
Solution Approach 2:
The insulator structure is designed to self-align and self-position the contact solder tails during assembly. The insulator's geometry automatically ensures that all solder tails are in the correct coplanar position and orientation, eliminating the need for complex alignment procedures and reducing the risk of unsoldered joints.
3Productivity
If conventional connectors use non-coplanar solder tails, then assembly can proceed, but mis-alignment occurs making soldering difficult and increasing assembly complexity
Solution Approach 1:
The contacts and insulator are pre-assembled with built-in alignment features that ensure coplanar solder tail configuration before the connector reaches the circuit board. This preliminary positioning eliminates the need for complex alignment operations during final assembly, simplifying the soldering process and improving productivity.
Solution Approach 2:
All contact solder tails are designed with uniform coplanar geometry and identical orientation relative to the insulator. This homogeneity allows for standardized soldering procedures and fixtures, reducing assembly complexity and enabling automated soldering processes, thereby improving productivity.
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 solution enables cost-effective and reliable assembly of communication systems by ensuring proper alignment and secure termination of contacts to the circuit board, reducing the risk of connector failure and improving assembly efficiency.
Implementation Method 1
The signal mounting ends include deflectable spring beams being deflected against the circuit board when the communication connector is mounted to the circuit board
Implementation Method 2
The ground mounting ends include compliant pins configured to be press-fit into plated vias of the circuit board
Data Source
AI summary
A receptacle connector assembly includes a receptacle cage mounted to a circuit board having walls defining a cavity including a module channel that receives a pluggable module. The receptacle connector assembly includes a communication connector received in the cavity and mounted to the circuit board. The communication connector has a housing holding a contact array including ground and signal contacts extending between mating and mounting ends of the housing. The ground contacts have ground mating ends and ground mounting ends including compliant pins press-fit into plated vias of the circuit board. The signal contacts have signal mating ends and signal mounting ends including deflectable spring beams deflected against the circuit board when the communication connector is mounted to the circuit board.