Dual-PCB Cable Termination for Connector Signal Integrity
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Solution Overview
Problem
Traditional methods for terminating twinax cables in network interface modules using paddle connectors face challenges in achieving performance thresholds, managing cable assembly, testing individual segments, and exchanging or reworking cables efficiently.
Innovation Solution
The use of a first PCB and a second PCB with an optional elastomer layer to electrically isolate cable and IO connector pin terminations, allowing for easier handling and assembly, reduced manufacturing mistakes, and improved signal integrity by keeping protrusions close to terminations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional paddle connectors are used to terminate twinax cables, then cable termination can be achieved, but performance thresholds cannot be met and signal integrity deteriorates
Solution Approach 1:
The invention divides the connector system into two separate PCBs: a first PCB for terminating cable ends and a second PCB for receiving IO connector pins. This segmentation eliminates the need for paddle connectors, improves signal integrity by providing dedicated termination points, and simplifies the manufacturing process by allowing independent assembly and testing of each PCB.
Solution Approach 2:
The invention extracts the cable termination function from the IO connector assembly by using separate PCBs. The first PCB is dedicated solely to cable termination while the second PCB handles IO connector pins, removing the performance-limiting paddle connector component entirely and enabling independent optimization of each subsystem.
2Ease of operation
If cables are terminated using traditional methods, then connection is established, but managing cable assembly and testing individual segments becomes difficult
Solution Approach 1:
By separating cable termination onto a dedicated first PCB, the invention enables independent handling, testing, and management of cable connections. Each cable can be terminated and tested individually on the first PCB before assembly with the second PCB, simplifying quality control and assembly management.
3Ease of repair
If cables are terminated in integrated connectors, then space is saved, but exchanging or reworking cables becomes inefficient
Solution Approach 1:
The separation of cable termination (first PCB) from IO connector pins (second PCB) enables independent replacement and rework of cables without affecting the IO connector assembly. Defective cable terminations can be repaired or replaced on the first PCB independently, significantly improving maintenance efficiency.
4Productivity
If manufacturing processes are simplified, then production time decreases, but detection and correction of defective connections becomes more difficult
Solution Approach 1:
The invention enables early detection of defective connections during the cable termination process on the first PCB, before final assembly with the second PCB. This segmented approach allows for intermediate quality checks that identify defects early in manufacturing, preventing defective assemblies from proceeding to later stages and reducing overall rework.
Data Source
AI summary
In some aspects, the techniques described herein relate to an apparatus for connecting cables to Input Output (IO) connector pins, including: a first Printed Circuit Board (PCB) configured to receive terminal ends of a plurality of cables, wherein the terminal ends of the plurality of cables are electrically isolated from one another in the first PCB; a second PCB configured to receive a plurality of IO connector pins, wherein the plurality of IO connector pins are electrically isolated from one another in the second PCB; and wherein the first PCB is configured to join to the second PCB to connect each of the terminal ends of the plurality of cables to corresponding pins of the plurality of IO connector pins.