Extender Module Assembly for High-Density Orthogonal Connectors
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Solution Overview
Problem
Existing interconnection systems face challenges in achieving high density and desirable signal integrity for high-frequency signals, particularly in orthogonal configurations, due to limitations in connector design and manufacturing complexity.
Innovation Solution
The development of an orthogonal connector system using extender modules with signal conductors and shielding, where the extender modules are captured within a shell to form an array, allowing for a simple manufacturing process and efficient signal routing, enabling high-density interconnections with improved signal integrity across a wide frequency range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If orthogonal connector configuration is used for high-density interconnection, then connection density is improved, but signal integrity deteriorates at high frequencies
Solution Approach 1:
The connector is divided into separate modules: a first connector portion with signal conductors, a second connector portion with complementary contacts, and an extender module that bridges them. This segmentation allows each module to be optimized independently for both density and signal integrity, with the extender module specifically designed to maintain impedance control and reduce crosstalk while enabling compact orthogonal arrangement.
Solution Approach 2:
The extender module acts as an intermediary component between the first and second connector portions. It provides a controlled impedance path for signals while physically separating the mating interfaces, allowing orthogonal configuration without direct exposure of signal conductors to external interference. The extender module's shielding and controlled geometry mediate the signal transmission to maintain integrity despite the compact high-density arrangement.
2Reliability
If extender modules with shielding are used to maintain signal integrity, then signal quality is improved, but device complexity increases
Solution Approach 1:
The extender module combines multiple functions into a single integrated component: signal transmission, electromagnetic shielding, mechanical positioning, and structural support. By merging these functions into one module rather than separate components, the design reduces overall system complexity while maintaining signal quality through built-in shielding and controlled impedance pathways.
Solution Approach 2:
The extender module is designed as a universal component that can be used in various connector configurations and applications. It provides both signal transmission and shielding functions simultaneously, and can accommodate different signal conductor arrangements. This multi-functionality reduces the need for multiple specialized components, thereby simplifying the overall device structure while maintaining high signal quality.
3Ease of manufacture
If modular connector design is implemented for ease of manufacture, then manufacturing simplicity is improved, but interconnection density may be reduced
Solution Approach 1:
The extender module is designed to nest within the overall connector assembly, with the first and second connector portions mating around it. This nested arrangement allows the modular components to be assembled in a compact configuration that maintains high interconnection density. The modular extender module can be manufactured separately and then integrated into the final assembly, simplifying manufacturing while achieving space-efficient high-density interconnection.
Data Source
AI summary
A modular electrical connector with modular components suitable for assembly into a right angle connector may also be used in forming an orthogonal connector or connector in other desired configurations. The connector modules may be configured through the user of extender modules. Those connector modules may be held together as a right angle connector with a front housing portion, which, in some embodiments, may be shaped differently depending on whether the connector modules are used to form a right angle connector or an orthogonal connector. When designed to form an orthogonal connector, the extender modules may interlock into subarrays, which may be held to other connector components through the use of an extender shell. The mating contact portions on the extender modules may be such that a right angle connector, similarly made with connector modules, may directly mate with the orthogonal connector.