Midboard Connector Engagement Design for Short Stub Length
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Solution Overview
Problem
Existing electrical connectors for high-frequency signal transmission face challenges in maintaining signal integrity and efficiency due to stub resonance, tolerance stack issues, and mechanical reliability, particularly in high-density interconnections within electronic devices.
Innovation Solution
The development of high-frequency midboard connectors with stamped terminal assemblies overmolded with dielectric material, featuring angled terminals and precise engagement mechanisms to reduce stub resonance and improve signal integrity, while allowing for high-density connections and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used for high-frequency signal transmission, then assembly is straightforward, but signal integrity deteriorates due to stub resonance and tolerance stack issues
Solution Approach 1:
The terminal assembly is segmented into multiple individual terminals that are separately formed and then assembled together using a common insulating body, allowing each terminal to be optimized independently while reducing overall stub resonance and tolerance accumulation
Solution Approach 2:
The connector design changes the geometric parameters of terminals including angled configurations and optimized lengths to minimize stub resonance effects and improve signal integrity at high frequencies
2Quantity of substance
If high-density interconnections are implemented, then signal routing capacity increases, but manufacturing precision requirements worsen due to tighter tolerances
Solution Approach 1:
The connector is divided into modular terminal assemblies that can be manufactured separately with controlled tolerances and then assembled, preventing tolerance stack accumulation that would occur in fully integrated high-density connectors
Solution Approach 2:
A common insulating body serves as an intermediary component that holds multiple terminals in precise relative positions, enabling high-density interconnections while maintaining manufacturing precision through the mediating structure
3Productivity
If stamped terminal assemblies with dielectric overmolding are used, then manufacturing efficiency improves, but mechanical reliability may worsen due to potential bonding issues
Solution Approach 1:
The connector combines stamped metal terminals with dielectric material through overmolding, creating a composite structure that achieves both manufacturing efficiency and mechanical reliability through the synergistic properties of different materials
Solution Approach 2:
The manufacturing process merges stamping and overmolding operations into an integrated process, combining the efficiency of metal forming with the benefits of dielectric bonding in a single manufacturing flow
Data Source
AI summary
A midboard cable connector assembly with a board connector and a cable connector. The board connector has terminals precisely positioned with respect to engagement features. A cable connector likewise has terminals precisely positioned with respect to complementary engagement features. When the connectors are pressed together for mating, the terminals of one or both connectors deform, generating a force that separates the connectors until the engagement features engage and block further backward motion. As the mating position is defined by the locations of the engagement features, the connectors can be designed with low over travel and a resulting short stub length, which promotes high frequency performance. High frequency performance is further promoted by a ground conductor interconnecting the beams forming mating contact portions of ground terminals, reducing the length of unconnected segments and by a cable clamp plate with compliant compression features that reduce distortion of the cables.