Modular Connector Assembly with Segmented Contact Chambers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost of manufacturing different designs of receptacle connectors with varying numbers of signal conductors or spacing is a significant challenge, as it requires new molds and tooling setups, leading to expensive production costs.
Innovation Solution
A modular connector assembly with a housing containing individual chambers for contact assemblies, each with a dielectric body holding differential pairs of receptacle signal contacts and a ground shield for electrical shielding, allowing for easy reconfiguration and reduced manufacturing costs by using the same contact assemblies in different configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If new molds and tooling setups are designed and manufactured for different connector designs, then manufacturing precision and design flexibility are improved, but manufacturing cost increases significantly
Solution Approach 1:
The connector is divided into separate modular components: a reusable housing and interchangeable contact assemblies. Each contact assembly contains a specific configuration of signal conductors and ground shields that can be independently manufactured and then assembled into the housing, eliminating the need for new molds for different connector configurations.
Solution Approach 2:
A single universal housing design can accommodate multiple different contact assembly configurations. The housing serves multiple functions: providing structural support, electrical insulation, and a standardized interface for different contact assemblies, thereby reducing the need for multiple specialized mold setups.
2Ease of manufacture
If traditional receptacle connectors with fixed designs are used, then manufacturing process is simplified, but adaptability to different configurations is reduced
Solution Approach 1:
The connector system transitions from a fixed, monolithic design to a dynamic, reconfigurable system. Contact assemblies can be easily removed and replaced within the same housing, allowing the connector configuration to adapt to different applications without requiring complex manufacturing processes.
Solution Approach 2:
Different contact assembly configurations are pre-manufactured as standardized modules with consistent interfaces. This preliminary preparation of modular components allows for rapid reconfiguration of connectors by simply swapping pre-fabricated contact assemblies into the universal housing.
Data Source
AI summary
A modular connector assembly includes a housing having a mating end and a mounting end opposite the mating end. The mating end is configured to be mated with a header connector and the mounting end is configured to be mounted to a circuit board. The housing has a plurality of individual chambers separated by chamber walls. Contact assemblies are received in corresponding chambers. Each contact assembly has a dielectric body holding a differential pair of receptacle signal contacts configured to be terminated to the circuit board and mated with corresponding header signal contacts of the header connector. Each contact assembly has a ground shield coupled to an exterior of the dielectric body providing electrical shielding for the differential pair of receptacle signal contacts from other pairs of receptacle signal contacts.