Funnel-Shaped Signal Contact Assembly for Precise Connector Alignment

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Solution Overview

Problem

Existing high-speed twisted pair data connector assemblies face challenges in achieving accurate and reliable connections between male and female signal contacts, particularly in maintaining signal integrity and mechanical alignment at high data transmission rates.

Innovation Solution

The connector assembly features an elongated inner signal contact with a tube-like main section and a funnel-shaped end section, embedded in an insulating element with a cavity design that accommodates the signal contact. The funnel-shaped end section allows for pin movement, ensuring correct insertion of the male signal contact, while the insulating element provides a precise guide and mechanical stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a male signal contact is inserted into a female signal contact without guidance features, then the insertion process is simple, but the connection accuracy and alignment between contacts deteriorate

Engineering Contradiction:

Improveconnection accuracyVSAvoidconnector structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The insulating element acts as an intermediary component that provides guidance features (guide ribs, guide grooves, funnel-shaped sections) to mediate the insertion process between male and female signal contacts. This intermediary structure ensures accurate alignment and connection without requiring complex external guidance mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent introduces dimensional features to the insulating element (guide ribs protruding in one direction, funnel-shaped sections with specific angles) that create guidance in the insertion direction. By adding these dimensional elements to the insulating element, the connector achieves self-alignment capabilities without increasing overall structural complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If the insulating element provides tight guidance for signal contacts, then connection accuracy improves, but the risk of damage during insertion increases

Engineering Contradiction:

Improvealignment precisionVSAvoidcontact damage risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The funnel-shaped end section with its gradual tapering geometry serves as a cushioning feature that prepares the insertion path beforehand. The gradual narrowing guides the signal contact gently into position, distributing insertion forces over a longer distance and preventing sudden impacts that could cause damage to contacts or the insulating element.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent varies the geometric parameters of the guidance features along the insertion path. The funnel-shaped section has a specific angle range (5-45 degrees) that changes gradually, and the guide ribs have varying heights and positions. These parameter changes create a progressive guidance system that maintains alignment precision while reducing peak insertion forces.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the connector assembly is designed for high-speed data transmission, then signal integrity requirements increase, but the tolerance for dimensional variations decreases

Engineering Contradiction:

Improvesignal integrityVSAvoiddimensional tolerance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The insulating element serves multiple functions simultaneously: it provides electrical insulation between contacts, mechanical support for signal contacts, guidance features for accurate alignment, and structural framework for the entire connector assembly. This multi-functionality ensures that all components work together to maintain consistent dimensional relationships, thereby preserving signal integrity at high speeds.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The connector assembly is segmented into distinct functional components (insulating element, signal contacts, shielding elements) with clearly defined interfaces. The insulating element is further segmented into regions with different functions (reception region, guide region, support region). This segmentation allows each component to be optimized for its specific function while maintaining precise dimensional relationships at interfaces, which is critical for high-speed signal integrity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12322894B2Connector assembly with funnel-shaped signal contact end section

Publication Date: 2025.06.03 APTIV TECHNOLOGIES AG

AI summary

A connector assembly includes at least one elongated inner signal contact having a first connection portion. The first connection portion includes a tube-like main section and a funnel-shaped end section. The first connection portion further includes an insulating element. The insulating element defines at least one elongated cavity designed to accommodate the elongated inner signal contact. A maximum outer cross-sectional dimension of the funnel-shaped end section is greater than a minimum cross-sectional dimension of the elongated cavity.