High-Density Connector Locking for Vibration-Resistant Data Links
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Solution Overview
Problem
Existing electrical connectors face challenges in connecting spaced-apart printed circuit boards and maintaining reliable, high-speed, high-density connections in harsh environments, such as automobiles, due to spacing limitations and vulnerability to vibrations.
Innovation Solution
A high-speed, high-density electrical connector system with a housing assembly, conductive pads, and a connector position assurance (CPA) device featuring multiple locking features and operating members to secure and maintain connections, ensuring reliable engagement and disengagement in various directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connectors are mounted on printed circuit boards spaced far apart, then assemblies can be interconnected through cables, but connection reliability deteriorates due to vibrations and disconnection risks in harsh environments
Solution Approach 1:
The CPA device incorporates a resilient beam that can dynamically deflect and absorb vibration forces. The locking feature is designed to pivot between locked and unlocked positions, allowing it to adapt to vibrational movements while maintaining secure engagement. This dynamic design enables the connector to withstand harsh environmental vibrations without disconnection.
Solution Approach 2:
The resilient beam acts as a cushioning element that anticipates and absorbs vibration forces before they can cause disconnection. By incorporating this energy-absorbing mechanism in advance, the connector is protected from the harmful effects of vibrations in harsh environments, preventing premature failure.
2Quantity of substance
If conductive pads are arranged in high-density configurations with pitch less than or equal to 1.0 mm, then data transmission capacity increases, but manufacturing precision requirements worsen
Solution Approach 1:
The connector is divided into modular components: a housing assembly, a separate module containing the high-density conductive pads, and a CPA device. This segmentation allows the high-density pad array to be manufactured and tested as an independent module, reducing the overall manufacturing precision burden while maintaining high data transmission capacity through the densely packed conductive pads.
3Reliability
If multiple locking features are implemented in the CPA device, then connection security improves, but device complexity worsens
Solution Approach 1:
Multiple locking features are integrated into a single unified CPA device structure. The first and second locking features are combined within one housing assembly, sharing common structural elements and mounting mechanisms. This merging approach maintains high connection security through multiple locking points while reducing overall device complexity compared to having separate locking mechanisms.
4Speed
If conductive pads are positioned at pitch less than or equal to 1.0 mm for high-speed transmission, then transmission rate improves, but susceptibility to harmful factors worsens
Solution Approach 1:
The high-density conductive pads are nested within a protective module that is itself housed within the housing assembly. This nested structure provides multiple levels of protection: the module housing shields the closely spaced conductive pads from external harmful factors such as EMI and physical damage, while allowing the pads to maintain their high-density configuration for fast data transmission.
Data Source
AI summary
Reliable high-speed, high-density connectors and interconnection systems thereof. An interconnection system includes a plug connector and a receptacle connector. The plug connector comprises a housing assembly, a module, and a CPA device. The module includes densely disposed conductive pads. The module can include a circuit board with the conductive pads and high-speed data cables having ends mounted onto the conductive pads. The CPA device is disposed on the housing assembly, and configured for securing the plug connector to the receptacle connector. The CPA device can include locking features disposed on different sides of the housing assembly, which can improve reliability. The receptacle connector includes an outer housing having complementary locking features. The connectors can be electrically connected as long as a first locking feature in its locked position. Such techniques can enable interconnection systems for harsh environments such as one presented by an automobile.