Flexible Plug Connector with Rigid Cavity for EMI Reduction
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Solution Overview
Problem
Existing electrical connectors face challenges in reducing crosstalk and electromagnetic interference (EMI) without increasing spatial demands, making it difficult for small cable gauges to fit on printed circuit boards while maintaining performance.
Innovation Solution
The use of flexible substrates with signal contacts that form a plug connector, allowing for staggered or offset cable arrangements to reduce stress and improve spatial efficiency, while maintaining performance by incorporating a rigid section within the connector to facilitate bending and reduce trace loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If small gage cables are used to reduce spatial demands, then spatial efficiency is improved, but crosstalk and EMI increase
Solution Approach 1:
The patent transitions from planar cable arrangement to three-dimensional staggered positioning. Cables are arranged in multiple vertical layers with offset horizontal positions, utilizing the Z-dimension to separate signal pairs. This spatial separation in three dimensions reduces electromagnetic coupling between adjacent pairs while maintaining compact footprint on the PCB.
Solution Approach 2:
The patent implements nested grounding where ground conductors are positioned between signal pairs in a layered configuration. The ground shields are embedded within the cable structure, creating concentric shielding arrangements that contain electromagnetic fields and reduce crosstalk between adjacent cable assemblies.
2Object-affected harmful factors
If cables are staggered to reduce crosstalk, then EMI is reduced, but trace loss increases
Solution Approach 1:
The patent modifies the geometric parameters of the cable arrangement, specifically the vertical spacing and horizontal offset distances between signal pairs. By optimizing these dimensional parameters, the design achieves sufficient electromagnetic isolation to reduce crosstalk while maintaining trace lengths and impedances that minimize signal attenuation and trace loss.
Solution Approach 2:
The patent applies different grounding and shielding configurations to specific regions of the cable assembly. Ground conductors are strategically positioned between signal pairs in high-interference regions, while maintaining optimized trace geometries in signal transmission paths to balance EMI reduction with minimal trace loss.
3Area of stationary object
If flexible substrates are used to improve spatial efficiency, then spatial demands are reduced, but structural stability worsens
Solution Approach 1:
The connector is divided into distinct rigid and flexible segments. The rigid substrate provides stable mounting for the mating connector interface, while flexible substrate sections enable cable routing and staggering arrangements. This segmentation allows each portion to perform its optimal function without compromising overall structural integrity.
Solution Approach 2:
The patent employs composite construction combining rigid and flexible substrate materials in a single connector assembly. The rigid portions provide mechanical stability and precise positioning, while flexible portions enable spatial efficiency and cable management, creating a hybrid structure that balances both requirements.
Data Source
AI summary
An electrical device including a plug connector. The plug connector includes a first flexible substrate having a plurality of signal contacts, the first flexible substrate extending from a terminating end to a mating end and configured to be flexible between the terminating end and mating end. A second flexible substrate extends in parallel spaced relation to the first flexible substrate to form a cavity between the first flexible substrate and second flexible substrate. The second flexible substrate having a plurality of signal contacts. The second flexible substrate extends from a terminating end to a mating end and configured to be flexible between the terminating end and mating end. The plug connector includes a rigid section disposed in the cavity at the mating end, the first flexible substrate moves in relation to the rigid section.