Cable Card Ground Bus Structure for Solderless Shield Termination
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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 cable card assembly with a separate and discrete ground bus that is electrically connected to the ground shields of the cables, featuring a molded body with tunnels to control impedance and provide shielding for the signal conductors, allowing for solderless connections and improved assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drain wire is soldered to a ground conductor, then reliable electrical connection is achieved, but assembly time and cost increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical system) with a mechanical press-fit connection system. The ground bus features a receptacle that mechanically receives and secures the drain wire through a press-fit mechanism, eliminating the need for soldering while maintaining reliable electrical connection between the drain wire and ground conductor.
Solution Approach 2:
The ground bus serves as an intermediary component that provides both mechanical support and electrical connection. It includes a receptacle for mechanical engagement with the drain wire and simultaneously provides electrical connection to the ground conductor, consolidating two functions into one component and eliminating the need for separate soldering operations.
2Reliability
If the drain wire is soldered to a ground conductor, then reliable electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical system) with a mechanical press-fit connection system. The ground bus features a receptacle that mechanically receives and secures the drain wire through a press-fit mechanism, eliminating the need for soldering while maintaining reliable electrical connection between the drain wire and ground conductor.
Solution Approach 2:
The ground bus is designed to automatically establish electrical connection through its press-fit receptacle mechanism. When the drain wire is inserted into the receptacle, the mechanical engagement itself creates the electrical connection without requiring external soldering operations, making the assembly process self-sufficient and reducing manufacturing complexity.
3Productivity
If a separate ground bus is used instead of soldering, then assembly efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the ground bus component: it provides electrical connection to ground conductors, mechanical support for the drain wire, and a press-fit receptacle for automated assembly. By merging these functions into a single component, the overall device complexity is managed while achieving improved assembly efficiency through the integrated design.
Solution Approach 2:
The ground bus serves multiple functions simultaneously: it acts as an electrical conductor for ground connection, provides mechanical support and positioning for the drain wire, and includes a receptacle structure that enables automated press-fit assembly. This multi-functionality reduces the need for separate components and operations, improving productivity while maintaining reasonable complexity.
Data Source
AI summary
A cable card assembly includes a circuit card having cable conductors at a cable end and cables terminated to the circuit card having signal conductors and ground shields surrounding the corresponding signal conductors to provide electrical shielding for the signal conductors. The signal conductors include exposed portions terminated to corresponding cable conductors. The cable card assembly includes a ground bus electrically connected to the ground shields. The ground bus includes a molded body having tunnels receiving the exposed portions of corresponding signal conductors. The molded body is contoured to control impedance along the exposed portions of the signal conductors.