Electrical Connector ESD Protection via Contact Routing

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Solution Overview

Problem

Electrical connectors face issues with electrostatic discharge (ESD) damage due to exposure of conductive terminals, which can lead to damage or destruction of semiconductor devices, especially when ambient humidity is low and human contact occurs, and existing ESD protection methods may not adequately prevent ESD on signal contacts.

Innovation Solution

An electrical connector design featuring an insulative housing with a tongue structure that includes upper and lower contacts, where the upper contacts have a bending section that extends through a passageway to the lower side, creating an intervening spacing to prevent contact with the plug's shell and thus reducing the risk of ESD, combined with a conductive outer shield for grounding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conductive terminals are exposed for engagement with mating connector, then electrical connection is enabled, but electrostatic discharge can damage semiconductor devices

Engineering Contradiction:

Improveelectrical connectionVSAvoidelectrostatic discharge

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A non-conductive coating is applied to the conductive terminals, creating an intermediary layer that prevents direct contact between electrostatic discharge sources and the electrical contacts. This coating acts as a mediator that blocks harmful ESD while allowing the terminals to maintain their electrical connection function when properly mated.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The non-conductive coating is applied in advance to the conductive terminals before assembly, providing preliminary protection against electrostatic discharge. This pre-applied protective layer prevents ESD damage before any harmful discharge can occur during connector mating or handling.

Inventive Principle:

Principle #9Preliminary anti-action

2Object-affected harmful factors

If shield is added for ESD protection, then electrostatic discharge protection is improved, but device complexity increases

Engineering Contradiction:

Improveelectrostatic discharge protectionVSAvoidconnector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The ESD protection function is extracted from the traditional shield structure and applied directly to the conductive terminals through a non-conductive coating. This eliminates the need for separate shield components, reducing device complexity while maintaining ESD protection effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The ESD protection function is merged with the conductive terminals themselves by applying the non-conductive coating directly to them. This combines the electrical connection function and ESD protection function into a single integrated component, simplifying the overall connector structure.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If non-conductive coating is applied to conductive terminals, then ESD protection is improved, but manufacturing process complexity increases

Engineering Contradiction:

Improveelectrostatic discharge protectionVSAvoidcoating application process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The coating application process utilizes parameter changes in the form of electrostatic charging, where the coating material is charged and attracted to the conductive terminals. This electrostatic application method simplifies the manufacturing process compared to traditional coating methods, as it requires no complex masking or alignment procedures.

Inventive Principle:

Principle #35Parameter changes

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 design effectively mitigates ESD risks by preventing upper contacts from shorting with the plug's shell, protecting both the connector and connected devices from electrostatic discharge, while allowing proper mating and grounding for safety.

Implementation Method 1

When mating the connectors, opposite charges at the connector interface may result in an ESD between the two connectors. In fact, electrostatic discharges can be generated simply by a person approaching or touching the connector interface or touching the terminal contacts.

Methodology Applied

Scientific EffectElectrostatic discharge: Electrostatic Discharge

Data Source

PatentUS7666030B2Electrical connector with ESD protection

Publication Date: 2010.02.23 HON HAI PRECISION INDUSTRY CO LTD

AI summary

An electrical connector has an insulative housing (10) and a number of electrical contacts (20). The insulative housing has a tongue (14, 15) defining a front face (145) and an upper side and a lower side perpendicular to the front face. The electrical contacts include a number of upper contacts (21) and lower contacts (22). The lower contacts are arranged on the lower side of the tongue and each including a contact section. The upper contacts each includes an extending section (212) arranged on the upper side of the tongue. A contact section (215) is bending from a side edge of the extending section of the upper contact and extending through a passageway (147) of the tongue for arranging on the lower side and avoiding the upper contacts shorting to a metal shell of a mating plug.