ESD-Protected Electrical Connector Insulator Design

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Solution Overview

Problem

Electrical connectors face issues with electrostatic discharge (ESD) damage due to exposure of conductive terminals, which can occur even when mating with other connectors, leading to potential damage to semiconductor devices, especially when ambient humidity is low.

Innovation Solution

An electrical connector design featuring an insulative housing with a base and tongue portion, including first and second electrical contacts, and an insulator to prevent contact between these contacts and the shell of a mating plug, thereby preventing improper connections and ESD.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conductive terminals are exposed for engagement with mating connector, then electrical connection is enabled, but electrostatic discharge damage occurs to semiconductor devices

Engineering Contradiction:

Improveelectrical connectionVSAvoidelectrostatic discharge damage

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

An insulator is introduced as an intermediary element positioned between the conductive terminals and the shell of the mating plug. The insulator prevents direct contact between the shell and signal contacts, thereby blocking the ESD pathway while allowing electrical connection to proceed. This mediator resolves the contradiction by enabling normal operation without exposing the system to harmful ESD effects.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If shield is added to provide ESD protection, then electrostatic discharge protection is improved, but device complexity increases

Engineering Contradiction:

Improveelectrostatic discharge protectionVSAvoidconnector structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of implementing a comprehensive shield throughout the connector, the insulator is strategically positioned only at the critical location where the shell could contact signal contacts. This localized approach provides ESD protection precisely where needed without adding unnecessary complexity to the overall connector structure.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If insulator is added to prevent contact between contacts and shell, then ESD protection is improved, but manufacturing complexity increases

Engineering Contradiction:

ImproveESD protectionVSAvoidconnector assembly

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The insulator is integrated with the existing connector housing structure, merging two previously separate components (insulator and housing) into a unified assembly. This integration reduces the total number of parts and simplifies manufacturing processes while maintaining the ESD protection function.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7445505B1Electrical connector with ESD protection

Publication Date: 2008.11.04 HON HAI PRECISION INDUSTRY CO LTD

AI summary

An electrical connector (100) for receiving a mating plug (200) having a number of plug contacts and a metal shell. The electrical connector has an insulative housing (10) provided with a base portion (13) and a tongue portion (14, 15) extending forwardly from the base portion. A set of first electrical contacts (21) and a set of second electrical contacts (22) are arranged in the isulative housing for engaging with the plug at a front and a rear position respectively. Each contact (21, 22) includes a contact section (214, 222) electrical connected with the contacts of the plug. An insulator (40) is located in front of the first electrical contacts for avoiding an improper connection between the contacts and the plug.