3D Lead-Frame Tabs for Crosstalk Reduction in Connectors
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Solution Overview
Problem
Existing connectors experience undesired cross-talk due to the close spacing between conductors, which current technologies are unable to adequately mitigate, especially when the conductive plate is electrically floating.
Innovation Solution
A connector design featuring a conductive plate with laterally extended tabs or protrusions from the lead-frames, which provide capacitive or conductive coupling to the conductive plate, effectively grounding it and reducing crosstalk by creating a three-dimensional lead configuration, with the tabs either capacitively or conductively coupled to the plate, thereby increasing isolation between leads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conductors are spaced closely together in connectors, then connector compactness is improved, but cross-talk between conductors increases
Solution Approach 1:
A conductive plate is introduced as an intermediary element positioned between adjacent conductors. This plate acts as a shield that blocks electromagnetic fields from coupling between neighboring conductors, thereby reducing crosstalk while allowing the conductors to remain in close proximity for compact connector design
Solution Approach 2:
The solution transitions from a two-dimensional planar arrangement of conductors to a three-dimensional configuration by adding the conductive plate dimension. The plate extends in the z-direction (thickness direction) to provide shielding, creating a layered structure that reduces crosstalk without increasing the footprint area
2Object-generated harmful factors
If a conductive plate is added between insulators to reduce crosstalk, then cross-talk reduction is improved, but device complexity increases
Solution Approach 1:
The conductive plate is merged with the lead-frame structure by forming tabs that extend from the lead wires and make direct contact with the conductive plate. This integration eliminates the need for separate mounting operations and reduces the number of discrete components
Solution Approach 2:
The lead wires are formed with tabs that are pre-configured to contact the conductive plate during the molding process. This preliminary configuration ensures proper electrical connection is established automatically when the insulating material is molded over the assembly, eliminating subsequent assembly steps
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
This design significantly reduces crosstalk between conductive leads by establishing a low impedance RF path and providing an effective RF ground for the conductive plate, enhancing signal integrity in connector systems like USB 3.1 Type-C connectors.
Implementation Method 1
at least one lead having at least one tab or extension which capacitively or conductively couples the lead to the conductive plate
Implementation Method 2
at least one lead having at least one tab or extension which capacitively or conductively couples the lead to the conductive plate
Implementation Method 3
effectively grounding it and reducing crosstalk by creating a three-dimensional lead configuration
Data Source
AI summary
A connector (400), such as a plug or a receptacle, has reduced cross-talk. The connector has a conductive plate (305), first and second insulators (310A, 310B) on either side of the conductive plate, leads (115) outside of the insulators, the leads being formed from first and second lead-frames, at least one of the leads (115, 315) having at least one tab or extension (320) which capacitively or conductively couples the lead to the conductive plate. The plate (305) may include an extension shaft (540), and a lateral extension (320) from a lead may be placed into contact with the shaft. A lateral extension (320E) formed on a rear portion of a lead may be placed into contact with a rear portion of the conductive plate (305B1) or with an opposing lead. Some of the leads may include severable tie bars (705).