Leadframe Electrical Connector Coplanar Transition Contacts
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Solution Overview
Problem
Existing electrical connectors face challenges with signal loss, signal degradation, and increased complexity due to the need for higher density and reduced size, which strains performance and increases costs, especially when using multiple leadframes and redundant contacts.
Innovation Solution
The design incorporates a contact module with a stamped and formed leadframe surrounded by a unitary dielectric frame, featuring coplanar transition contacts and vertically staggered mating contacts, which allows for increased density and robustness while reducing material usage and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple overmolded leadframes are used to position contacts close together, then contact density increases, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate leadframes into a single integrated leadframe structure. The leadframe contains multiple signal conductors with transition contacts and mating contacts all formed from a single piece of conductive material, eliminating the need for multiple separate leadframes that would need to be internested. This reduces assembly complexity while maintaining high contact density.
Solution Approach 2:
The single leadframe is segmented into multiple functional regions including transition contacts encased in the dielectric frame and mating contacts extending outward. This segmentation allows different portions of the single leadframe to perform different functions (transition vs. mating contacts) while maintaining structural integration and reducing overall complexity.
2Manufacturing precision
If contacts are arranged in a single contact plane, then manufacturing precision is improved, but contact density is limited
Solution Approach 1:
The patent transitions from a two-dimensional single-plane contact arrangement to a three-dimensional configuration. The mating contacts extend outward from the contact plane in a third dimension, allowing additional contacts to be added without compromising the precision of the original coplanar transition contacts. This vertical arrangement increases contact density while preserving manufacturing precision for the transition contacts.
3Reliability
If redundant or multiple points of contact are used, then reliability improves, but material usage and manufacturing cost increase
Solution Approach 1:
The patent combines multiple contact functions into a single integrated leadframe structure rather than using separate redundant contacts. The single leadframe provides both transition contacts encased in the dielectric frame and mating contacts extending outward, eliminating the need for multiple separate contact elements and reducing overall material consumption while maintaining reliability.
Data Source
AI summary
An electrical connector includes a contact module having a leadframe and a dielectric frame surrounding the leadframe. The leadframe has signal conductors having transition contacts encased in the dielectric frame. The transition contacts are coplanar such that the transition contacts are arranged within a contact plane of the leadframe. The signal conductors have mating contacts extending from the corresponding transition contacts. Each of the mating contacts have a mating interface configured to be electrically connected to a corresponding mating contact of a mating connector. The mating contacts are arranged in pairs with the corresponding mating interfaces aligned in rows along corresponding row axes. Each of the pairs of mating contacts are arranged in different rows.