Orthogonal Board Connector With Twisted Contacts and Shielded Mating
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Solution Overview
Problem
The design and manufacture of high-speed electrical connectors for direct plug orthogonal communication systems are complex and costly due to the need for two distinct right-angle connector designs, often requiring additional adapter connectors, which increases expenses.
Innovation Solution
The development of an electrical connector with a housing and wafer assemblies that include twisted signal contacts and ground shields, providing a hermaphroditic mating interface that allows for direct orthogonal connection between two identical circuit board assemblies without the need for additional adapters, utilizing a commoning member for enhanced shielding.
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 device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single right-angle connector that can mate with itself in orthogonal configurations. The connector features identical signal contacts and ground shields on both sides, allowing it to serve as either male or female connector, eliminating the need for two distinct connector designs while maintaining reliable signal transmission between perpendicular circuit boards.
Solution Approach 2:
The patent merges the functions of two different right-angle connectors into a single universal connector design. By integrating identical signal contact arrays and ground shield structures on both mating surfaces, the connector combines the roles of what were previously separate male and female right-angle connectors, reducing device complexity and standardizing the interface.
2Shape
If two distinct right-angle connector designs are used, then orthogonal connection is achieved, but manufacturing cost increases due to tooling investments
Solution Approach 1:
The universal right-angle connector design allows a single tooling setup to produce connectors for both sides of the orthogonal connection. By making the connectors identical and self-mating, the manufacturer needs only one set of molds and tooling fixtures, significantly reducing manufacturing cost while maintaining the orthogonal connection capability.
Solution Approach 2:
The patent employs homogeneity by making both connectors in the orthogonal pair identical in design, dimensions, and manufacturing process. This uniformity allows for standardized production using the same tooling for both connectors, eliminating the need for separate tooling investments and reducing overall manufacturing cost while preserving the right-angle connection geometry.
3Reliability
If adapter connectors are used between first and second connectors, then connection is achieved, but device complexity and expense increase
Solution Approach 1:
The patent eliminates the need for adapter connectors by merging the functionality of the first and second connectors into a single universal design. The identical signal contacts and ground shields on both mating surfaces allow direct mating without requiring an intermediate adapter, thereby reducing device complexity and the number of components in the connector system.
Solution Approach 2:
The universal right-angle connector can directly mate with another identical connector in orthogonal configuration, making adapters unnecessary. The connector's dual-sided identical design allows it to function as both the first and second connector in the assembly, eliminating the need for additional adapter components while maintaining reliable electrical connection.
4Reliability
If shielding is added to high speed connectors, then signal integrity is improved, but device complexity increases
Solution Approach 1:
The patent applies homogeneity by using identical ground shield structures on both sides of the universal connector. This uniform shielding approach provides consistent signal integrity protection across all signal paths while simplifying the design process, as the same shielding configuration can be replicated on both mating surfaces without requiring complex asymmetric designs.
Solution Approach 2:
The universal connector design incorporates shielding that serves both connectors simultaneously. The identical ground shields and signal contact arrangements on both sides mean the shielding structure fulfills the electromagnetic interference protection function for both mating connectors, reducing overall device complexity compared to designing separate shielding systems for each connector type.
Data Source
AI summary
An electrical connector includes wafer assemblies coupled to a housing. Each wafer assembly includes a leadframe, a wafer body holding the leadframe, and a ground frame coupled to the wafer body to provide electrical shielding for the leadframe. Each leadframe has signal contacts with mating ends extending from the wafer body for mating with mating signal contacts of a mating electrical connector. The mating ends are twisted 45° to define twisted mating interfaces. Each ground frame has ground shields extending from a ground plate along the mating ends of the signal contacts. The ground shields are twisted 45° relative to the ground plate to define twisted shield zones along the mating ends of the signal contacts.