Electrical Connector Ground Bar Layout for Simpler Ground Wire Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing PCI-E electrical connectors have complex manufacturing processes and high costs due to the large number of small-sized ground terminals requiring precise alignment and connection to ground wires.
Innovation Solution
The electrical connector design includes a ground bar with extension portions that allow multiple ground wires to be connected directly to the ground bar, eliminating the need for individual alignment and connection to each ground terminal, simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple small-sized ground terminals are used to connect ground wires, then signal integrity is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple separate ground terminals are merged into a single ground bar structure with multiple connection points. The ground bar integrates the functionality of multiple ground terminals while providing a unified structure that simplifies the manufacturing process by reducing the number of discrete components that need to be individually handled and assembled.
Solution Approach 2:
The ground bar serves multiple functions simultaneously: it provides multiple ground connections for signal integrity, acts as a common reference plane, and simplifies the manufacturing process. This multi-functional design eliminates the need for separate ground terminals while maintaining all necessary grounding functions.
2Reliability
If multiple small-sized ground terminals are used to connect ground wires, then grounding effectiveness is improved, but manufacturing cost increases
Solution Approach 1:
The ground bar combines multiple ground terminal functions into a single integrated component, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation reduces manufacturing costs while maintaining effective grounding through multiple connection points on the ground bar.
Solution Approach 2:
The ground bar is segmented into multiple connection portions along its length, allowing multiple ground wires to be connected at different locations. This segmentation provides the grounding effectiveness of multiple terminals while using a single unified structure that is more cost-effective to manufacture than multiple separate terminals.
3Manufacturing precision
If individual alignment and connection to each ground terminal is required, then connection precision is improved, but manufacturing time increases
Solution Approach 1:
Multiple ground wire connections are merged into a single assembly operation where all ground wires are connected to the ground bar simultaneously or in sequence without requiring precise individual alignment to separate terminals. The ground bar's extended structure provides multiple accessible connection points that simplify the connection process.
Solution Approach 2:
The ground bar is pre-positioned and secured in the connector housing before ground wire connections are made. This preliminary positioning establishes a stable reference structure that guides the connection process, reducing the time and precision required for each individual connection while ensuring proper alignment.
Data Source
AI summary
An electrical connector includes an insulating housing, a terminal holder, two terminal groups, and a ground bar. The insulating housing has a slot. The terminal holder is disposed in the insulating housing. The two terminal groups are disposed in the insulating housing. The two terminal groups are arranged oppositely and fixed on the terminal holder, and each of the two terminal groups includes signal terminals and ground terminals that are arranged along a first direction. The ground bar is disposed on the terminal holder and electrically connected to the plurality of ground terminals, and the ground bar is configured to be parallel with the first direction. The ground bar includes a plurality of extension portions connected to a first long side of the ground bar. Each of the extension portions is directly connected to a plurality of ground wires of a plurality of cables.