Electrical Terminal With Tapered Mounting End for High Pin Density
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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 optimized for reduced spacing and increased pin densities.
Innovation Solution
The electrical terminals have a smaller mounting end with a compliant portion featuring a slit and tapered segments, allowing for reduced insertion force, improved impedance, and increased pin density, while maintaining structural integrity for insertion into micro via apertures without damage.
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 the mechanical integrity and electrical performance (impedance, cross-talk) deteriorate
Solution Approach 1:
The terminal structure is designed with different geometries at different locations: the mounting end has a smaller cross-section with a slit for flexibility and reduced insertion force, while the mating end maintains larger dimensions for proper electrical performance. This local differentiation allows high pin density at the mounting end without compromising the electrical characteristics at the mating end.
Solution Approach 2:
The terminal is divided into distinct functional segments: a mounting end portion with reduced size and a slit for insertion into micro vias, and a mating end portion with optimized geometry for electrical connection. This segmentation allows each portion to be optimized independently for its specific function while maintaining overall terminal integrity.
2Force
If the mounting end of the terminal is made smaller for micro via insertion, then the insertion force is reduced and pin density is increased, but the structural integrity and electrical performance may deteriorate
Solution Approach 1:
A slit is formed through the mounting end of the terminal, creating a flexible structure that can elastically deform during insertion into micro vias. This flexibility reduces insertion force while maintaining structural integrity, as the material can bend and recover without permanent deformation or failure.
Solution Approach 2:
The terminal geometry is optimized by reducing the cross-sectional dimensions of the mounting end while maintaining or increasing the dimensions of the mating end. This parameter change allows the terminal to fit into smaller micro vias with lower insertion forces while preserving the electrical performance characteristics at the mating end.
3Reliability
If the terminal configuration is optimized for high speed electrical performance, then impedance and cross-talk are improved, but the insertion force and difficulty of installation increase
Solution Approach 1:
The terminal design applies different geometric optimizations to different portions: the mounting end features a reduced cross-section with a slit for easy insertion, while the mating end maintains optimized geometry for high-speed electrical performance. This local differentiation resolves the contradiction between ease of installation and electrical performance.
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. 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.