Electrical Connector Terminals With Tapered Mounting Ends
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Solution Overview
Problem
Existing high-speed electrical connectors face challenges in achieving desired impedance levels and reducing cross-talk while maintaining mechanical integrity, particularly due to the neglect of the mounting ends of electrical terminals, which are not adequately addressed by previous designs focusing solely on the mating ends.
Innovation Solution
The electrical terminals have a mounting end that is substantially smaller than the mating end, featuring a compliant portion with a slit and tapered segments, allowing for reduced insertion forces, improved impedance, and increased pin density, while maintaining structural integrity for insertion into panel member apertures of reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the spacing between electrical terminals is reduced to increase pin density, then the number of terminals per unit area increases, but impedance control and cross-talk reduction become more difficult
Solution Approach 1:
The patent applies local quality by differentiating the geometry of the terminal between its mounting end and mating end. The mounting end features a reduced diameter insertion portion that fits into micro vias, while the mating end maintains a larger diameter for proper signal transmission. This localized geometric variation allows high pin density at the mounting interface without compromising impedance control at the mating interface, as each portion is optimized for its specific function.
2Quantity of substance
If the spacing between electrical terminals is reduced to increase pin density, then the number of terminals per unit area increases, but cross-talk between adjacent terminals increases
Solution Approach 1:
The patent applies local quality by differentiating the geometry of the terminal between its mounting end and mating end. The mounting end features a reduced diameter insertion portion that fits into micro vias, while the mating end maintains a larger diameter for proper signal transmission. This localized geometric variation allows high pin density at the mounting interface without compromising impedance control at the mating interface, as each portion is optimized for its specific function.
3Area of stationary object
If the insertion portion diameter is reduced to enable micro via insertion, then the terminal can be inserted into smaller apertures, but the structural integrity and mechanical strength are reduced
Solution Approach 1:
The patent applies segmentation by dividing the terminal into distinct functional portions: an insertion portion with reduced diameter for micro via access, a body portion with intermediate dimensions providing structural support, and a mating end with larger diameter for electrical connection. This segmentation allows each portion to be optimized independently - the insertion portion fits small vias while the body and mating end maintain the structural integrity necessary for mechanical strength and electrical performance.
4Reliability
If the terminal geometry is modified to improve electrical performance, then impedance and cross-talk are reduced, but the insertion force required may increase
Solution Approach 1:
The patent applies parameter changes by optimizing the diameter and length of the insertion portion to create a press-fit mechanism that generates controlled insertion force. The reduced diameter of the insertion portion relative to the via hole creates an interference fit that provides both the necessary insertion force and strong mechanical retention. Simultaneously, the geometric parameters are tuned to maintain proper impedance characteristics, as the insertion portion dimensions are designed to match the via hole dimensions for optimal electrical performance while providing adequate mechanical strength.
Data Source
AI summary
An electrical terminal of the type to be inserted into an aperture of an electrical panel member is provided. The electrical terminal may include a base, an insertion portion extending from the base to a first end, a slit formed through the insertion portion and defining a compliant portion having a first leg and a second leg. A segment of the first leg may be deformed in one direction, while a segment of the second leg may deformed in the opposite direction. Midpoints of each or both legs may be offset from the midpoint of the slit to achieve improved mechanical and electrical performance within a connector. Also provided is an electrical terminal having a tip that facilitates alignment with a panel member aperture and provides tactile feedback to a user, as well as an electrical terminal having a mounting end that is substantially smaller than its mating end, and connectors containing such terminals. Methods of routing electrical traces between adjacent electrical terminals are also provided.