High Speed Data Contact Set with Protective Arms
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Solution Overview
Problem
Existing high-speed data contact systems are not adapted for high life-cycle or mass interconnect systems that require thousands or tens of thousands of connection cycles, lacking efficient alignment and protection mechanisms.
Innovation Solution
A high-speed data contact set with a hollow housing, protective arms, and a termination subassembly featuring a printed circuit board and shielded wires, along with a molded insulator and latch system for secure alignment and reduced unshielded wire length, enabling differential signal transmission at 10 Gigabits per second.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional high-speed data contact systems are used, then basic data transmission is achieved, but they cannot withstand thousands or tens of thousands of connection cycles required for high life-cycle systems
Solution Approach 1:
The patent implements multi-stage pre-alignment features including guide pins, alignment ribs, and tapered surfaces that prepare and position contact beams before final engagement. This preliminary alignment ensures contacts are properly positioned prior to mating, preventing misalignment damage during repeated connection cycles and extending device life-cycle durability
Solution Approach 2:
The contact system is divided into modular components including separate contact beams, protective arms, alignment features, and housing elements. This segmentation allows each component to be optimized for its specific function while working together to achieve high cycle life through controlled engagement sequences that reduce wear on individual elements
2Reliability
If protective arms are added to protect contact beams, then contact protection is improved, but device complexity increases
Solution Approach 1:
The protective arms are integrated with the housing structure and alignment features rather than being separate components. The arms are molded as part of the housing assembly, combining protection, alignment, and structural support functions into a single integrated component, thereby reducing overall device complexity while maintaining contact beam protection
Solution Approach 2:
The protective arms serve multiple functions simultaneously: they protect contact beams from damage, provide mechanical guidance during insertion, and contribute to the overall structural integrity of the housing. This multi-functionality reduces the need for separate protective components, maintaining simplicity while improving reliability
3Reliability
If shield strap covers are added to stripped wire ends, then signal integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The shield strap covers are integrated into the housing molding process rather than being separate assembly steps. The housing is molded with built-in shield straps that automatically cover the stripped wire ends during the molding process, eliminating the need for separate shielding components and reducing manufacturing complexity while maintaining signal integrity
Solution Approach 2:
The shield strap design utilizes the molding process parameters to automatically position and size the shielding coverage. By controlling the molding parameters, the shield straps are precisely formed to cover wire ends without requiring additional machining or assembly operations, simplifying manufacturing while ensuring adequate signal shielding
Data Source
AI summary
A high-speed data contact set having a housing with a hollow body having a top, a bottom, a front, a rear, and first side and a second side; a plurality of protective arms extending from the front of said hollow body for protecting contact beams of a termination subassembly inserted into said insert housing. The termination subassembly in said insert shroud, has a plurality of pairs of contact beams, a termination subassembly body molded on and around a central portion of the plurality of pairs of contacts, a printed circuit board connected to the pairs of contacts, and a plurality of wires each having a stripped end soldered to said printed circuit board. One end of each of said plurality of pairs of contacts is soldered to said printed circuit board, and a shield strap covers said stripped end of wire of said plurality of wires.