Enclosed Mated Pair Connector for High-Density PCB Signals
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Solution Overview
Problem
Conventional card edge connectors require an exposed printed circuit board, which poses safety risks, is not scalable, and is costly due to specialized designs, making them unsuitable for high-density electrical connections in complex systems.
Innovation Solution
A mated pair electrical connector utilizing printed circuit boards for high-density connections, where the connector components are fully enclosed, ensuring safety and scalability, and allowing for a large number of signals to be propagated at a lower manufacturing cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If card edge connectors are used to achieve high-density electrical connections, then the number of signals that can be connected increases, but safety risks increase due to exposed conductive surfaces
Solution Approach 1:
The patent embeds the conductive contacts within an enclosed connector housing that integrates the printed circuit board. The contacts are nested inside the housing structure rather than exposed on the board edge, allowing high-density connections while preventing direct exposure to the environment. This nesting approach resolves the contradiction by maintaining signal density while eliminating safety hazards from exposed conductors.
Solution Approach 2:
The patent uses a standardized printed circuit board design that can be easily manufactured and replaced. The enclosed connector housing protects the conductive elements, allowing for cost-effective manufacturing while maintaining safety. This approach enables high-density connections without the specialized, expensive custom designs required by traditional card edge connectors.
2Quantity of substance
If card edge connectors with exposed printed circuit boards are used, then high-density connections are achieved, but manufacturing cost increases due to specialized designs
Solution Approach 1:
The patent employs a universal printed circuit board design with standardized contact arrangements that can be used across multiple applications. The enclosed connector housing provides a generic platform that accommodates various signal densities without requiring custom board designs. This universality reduces manufacturing costs while maintaining the capability for high-density electrical connections.
Solution Approach 2:
The patent combines the printed circuit board, contact elements, and protective housing into an integrated connector assembly. This merging of components eliminates the need for separate specialized board designs and reduces manufacturing complexity. The integrated design achieves high-density connections at lower cost by consolidating functions into a single manufacturable unit.
3Reliability
If exposed printed circuit boards are used in card edge connectors, then electrical connections are established, but reliability decreases due to contamination and degradation
Solution Approach 1:
The patent uses an enclosed housing structure that acts as a protective shell around the conductive contacts and printed circuit board. This enclosure prevents contaminants, moisture, and other environmental factors from reaching the electrical contacts. The housing maintains reliable electrical connections by isolating the conductive elements from degrading environmental conditions throughout the product lifecycle.
4Reliability
If card edge connectors are designed for specific circuit boards, then connections are optimized, but adaptability decreases across different systems
Solution Approach 1:
The patent designs the connector with a standardized enclosed housing and contact arrangement that can interface with various printed circuit board configurations. The universal design allows the same connector type to be adapted to different systems and signal densities without requiring custom specialized designs, thereby improving both adaptability and maintaining connection reliability through standardized interfaces.
Data Source
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AI summary
A high density mated pair connector having a printed circuit board ("PCB") and a contact module to facilitate electrical connections through the mated pair connector. A receptacle assembly accepts receptacle cables and electrically connects the receptacle cables to a receptacle PCB coupled with a receptacle body. A plug assembly accepts plug cables and electrically connects the plug cables to a plug PCB coupled with a plug body. A contact module is coupled with the plug body and has a plurality of contacts. A first end of the plurality of contacts electrically connects with the plug PCB. A second end of the plurality of contacts is configured to electrically connect with the receptacle PCB. Upon mating, the plurality of contacts of the contact module couple to the receptacle PCB, thus electrically connecting the receptacle cables with the plug cables.