Orthogonal Board Connector With Twisted Pair Self-Mating Interface
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Solution Overview
Problem
The design and manufacture of high-speed electrical connectors for direct plug orthogonal communication systems are costly due to the need for two distinct right-angle connector designs, often requiring additional adapter connectors, which increases complexity and expense.
Innovation Solution
The use of identical electrical connectors with twisted signal and ground contacts, arranged in a wafer stack configuration, allows for direct mating of perpendicular circuit boards without an adapter, providing both signal transmission and shielding while reducing tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two distinct right-angle connector designs are used for direct plug orthogonal connections, then signal transmission between perpendicular circuit boards is achieved, but manufacturing cost and device complexity increase due to requiring two different connector designs and potential adapter connectors
Solution Approach 1:
The patent applies universality by designing a single right-angle connector that can mate with itself in either orientation (0 degrees or 180 degrees), eliminating the need for two distinct connector designs. The connector housing includes a mating interface that accepts connectors from both orientations, allowing the same connector type to serve multiple functions in perpendicular circuit board connections.
Solution Approach 2:
The patent merges the functionality of two different right-angle connector designs into a single universal connector. By combining the mating interface design to accommodate both 0-degree and 180-degree orientations, the invention consolidates what would traditionally require separate connector types into one unified design, reducing device complexity and manufacturing costs.
2Reliability
If two distinct right-angle connector designs are used, then proper signal transition between perpendicular boards is achieved, but manufacturing cost increases due to tooling investments for two individual designs
Solution Approach 1:
The universal connector design allows a single tooling setup to produce connectors that can be used in both 0-degree and 180-degree orientations. This eliminates the need for separate tooling investments for two different connector designs, directly reducing manufacturing costs while maintaining signal transition capability between perpendicular circuit boards.
3Adaptability or versatility
If adapter connectors are added between the first and second connectors, then compatibility is improved, but device complexity and expense increase
Solution Approach 1:
The patent eliminates the need for adapter connectors by designing the mating interface to directly accommodate connectors in both 0-degree and 180-degree orientations. The universal connector can mate with itself regardless of orientation, providing adaptability without requiring additional adapter components, thereby reducing system complexity.
4Reliability
If shielding is added to high-speed connectors, then signal integrity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the shielding design into the universal connector structure, using the same ground contacts and shielding configuration for both 0-degree and 180-degree mating orientations. This integrated approach provides signal integrity through shielding while avoiding the need for separate shielding designs for different connector types, thereby reducing overall device complexity.
Data Source
AI summary
An electrical connector includes a housing holding wafer assemblies in a wafer stack each including a wafer body holding a leadframe with signal contacts arranged in pairs and extending between mating ends and mounting ends. Each pair includes a primary signal contact and a secondary signal contact. Each signal contact has a main body extending through the wafer bodies and a mating end extend from the wafer body presented at the mating interface. The mating ends are twisted 45° relative to the main bodies. The mating end of the primary signal contact is arranged at a first side of the main body and the mating end of the secondary signal contact is arranged at a second side of the main body to define a twisted pair interface configured to be mated with the mating signal contacts of the mating electrical connector.