Connector With Overmolded Circuit Board Cable Assemblies
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Solution Overview
Problem
Existing connector assemblies for high-speed signal protocols face challenges in achieving low impedance while maintaining structural integrity, particularly during plugging and unplugging, and often rely on generic 1-piece hollow housings that are not suitable for high-density implementations.
Innovation Solution
A connector assembly featuring an insulative 2-piece housing with a removable upper and lower housing half, coupled with an overmold that encloses shielded cables and a printed circuit board, providing secure alignment and low impedance connections through conductive contact pads and shielding films, and conforming to SFF 8643 standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a generic 1-piece hollow housing is used, then manufacturing is simple, but structural integrity during plugging and unplugging deteriorates
Solution Approach 1:
The housing is divided into two separate halves (first housing half and second housing half) that are joined together. This segmentation allows each half to be manufactured independently with simpler processes, while the combined structure provides the structural integrity needed during plugging and unplugging operations.
2Device complexity
If a 1-piece hollow housing is used, then device complexity is reduced, but impedance control deteriorates
Solution Approach 1:
Dividing the housing into two halves enables precise control of impedance characteristics through optimized geometry of each half, while maintaining manageable device complexity through modular construction.
Solution Approach 2:
The two-half housing structure allows for localized optimization of impedance control in specific regions where cables and contacts are positioned, while other regions maintain simpler geometries.
3Reliability
If shielded cables with conductor sets are used, then signal integrity is improved, but device complexity increases
Solution Approach 1:
Multiple conductor sets within shielded cables are merged into a unified assembly that is collectively supported and positioned by the two-half housing structure, reducing overall device complexity while maintaining signal integrity.
Data Source
AI summary
A connector assembly includes a housing, a plurality of circuit board cable assemblies, and an overmold. Each of the circuit board cable assemblies includes a printed circuit board and a pair of shielded cables. The overmold extends and insulate a portion of the shielded cables and a portion of the printed circuit board that includes a plurality of conductive contact pads for electrical connection to the shielded cables.