Ground Block Drain Wire Channels for Solderless Connector Assembly
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Solution Overview
Problem
The termination of drain wires in electrical connectors is a time-consuming and costly process due to the need for soldering, which increases assembly time and cost.
Innovation Solution
A ground block is introduced that is separate from the circuit card and includes drain wire channels for receiving and electrically connecting drain wires, allowing for solderless connections such as press-fit or interference fits, reducing assembly time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drain wires are soldered to ground conductors, then reliable electrical connection is achieved, but assembly time and cost increase
Solution Approach 1:
The patent extracts the soldering process from the assembly procedure by introducing a ground block with pre-formed drain wire channels that accept drain wires through mechanical insertion. This separates the electrical connection function from the time-consuming soldering operation, allowing drain wires to be connected via simple press-fit or interference fit mechanisms while maintaining reliable electrical contact.
Solution Approach 2:
The ground block is pre-configured with drain wire channels that are designed to receive and electrically connect drain wires before final assembly. The channels are formed with appropriate conductivity and mechanical properties in advance, eliminating the need for on-site soldering operations and reducing assembly time.
2Reliability
If soldering process is used for drain wire termination, then secure electrical connection is achieved, but assembly cost increases
Solution Approach 1:
The patent removes the soldering operation from the manufacturing process by providing a ground block with integrated drain wire channels that enable mechanical connection methods. This extraction eliminates the need for soldering equipment, skilled soldering labor, and associated quality control steps, thereby reducing assembly cost while maintaining connection reliability through precise mechanical fits.
Solution Approach 2:
The patent replaces the thermal-chemical soldering process with a purely mechanical connection system. The drain wire channels are designed with specific geometries that create interference fits or press-fit connections, substituting the soldering joint with a mechanical joint that achieves reliable electrical connection without heat, flux, or solder material.
3Adaptability or versatility
If separate ground block is used instead of integrated ground structure, then assembly flexibility is improved, but device complexity increases
Solution Approach 1:
The patent divides the connector assembly into separate functional modules: the ground block with drain wire channels is distinct from the main connector body and circuit card. This segmentation allows the ground block to be manufactured independently, optimized for drain wire reception, and assembled separately, improving assembly flexibility and adaptability while managing complexity through modular design.
Solution Approach 2:
The ground block serves multiple functions: it provides electrical grounding, receives and secures drain wires through its channels, and establishes electrical connection between drain wires and ground conductors. This multi-functionality consolidates several operations into a single component, reducing overall assembly complexity despite the separate ground block structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of a separate ground block with drain wire channels facilitates faster and less expensive assembly by eliminating the need for soldering, thereby reducing the overall assembly time and cost while maintaining electrical connectivity.
Implementation Method 1
The separating walls provide electrical shielding for the signal conductors in the tunnels
Implementation Method 2
The ground block is electrically conductive to electrically connect the drain wires
Data Source
AI summary
A cable card assembly for an electrical connector includes a circuit card having upper and lower surfaces and extending between a cable end and a mating end with mating conductors at the mating end and cable conductors at the cable end. Cables are terminated to the circuit card that include signal conductors, ground shields surrounding the corresponding signal conductors, and drain wires electrically connected to the corresponding ground shields. The signal conductors are terminated to corresponding cable conductors. The cable card assembly includes a ground block separate and discrete from the circuit card and coupled to the circuit card. The ground block includes drain wire channels receiving corresponding drain wires. The ground block is electrically conductive to electrically connect the drain wires.