Pluggable Connector Assembly With Transverse Mating for Dense Contacts
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Solution Overview
Problem
Existing communication systems are limited by the contact density of card edge connectors and module circuit boards, which restrict the number of high-speed signals that can be transmitted.
Innovation Solution
An electrical connector system with a circuit card assembly and pluggable module design that includes a host circuit board, socket connector, guide rail, and pluggable module, featuring a module actuator and actuation features to facilitate transverse mating of module contacts with coplanar upper contacts, allowing for increased contact density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If card edge connectors with two rows of contacts are used, then the structure is simple and easy to manufacture, but the contact density is limited
Solution Approach 1:
The patent transitions from a traditional two-row contact arrangement on a flat circuit board to a three-dimensional contact array where contacts are arranged in multiple rows and columns on vertical walls of cavities. This dimensional change allows significantly higher contact density while maintaining a compact form factor, as contacts can be stacked vertically and arranged in a grid pattern across multiple faces of the connector housing.
Solution Approach 2:
The connector design nests multiple contact rows and columns within cavities formed in the housing structure. The contacts are arranged in a nested configuration where multiple contact arrays are contained within the three-dimensional space of the connector body, allowing dense packing of contacts without proportionally increasing the external dimensions of the connector.
2Quantity of substance
If more contacts are added to increase signal capacity, then the transmission capacity improves, but the contact density increases leading to more wear and damage risk
Solution Approach 1:
The contact array is segmented into multiple independent rows and columns arranged on different faces and within different cavities of the connector. This segmentation allows each contact to be independently positioned and mated, distributing the mechanical stress and wear across many discrete contact points rather than concentrating it on a few high-density contacts. The segmented arrangement also allows for modular assembly and replacement.
Solution Approach 2:
The connector design incorporates a mating operation that guides contacts into alignment before final engagement, and includes features such as compliant contact elements and distributed contact pressure across multiple rows and columns. This beforehand cushioning approach prevents excessive force on individual contacts during mating, reducing wear and damage risk while accommodating the high number of contacts required for high-speed signal transmission.
3Quantity of substance
If coplanar mating interfaces are used, then the mating operation is simplified, but the contact density is restricted
Solution Approach 1:
The patent extends the coplanar mating interface concept from a two-dimensional plane to a three-dimensional surface by arranging contact mating interfaces on multiple coplanar faces of the connector housing. The contacts on vertical walls and horizontal surfaces are positioned to mate with corresponding contacts on the circuit board in a coordinated fashion, maintaining the simplicity of a single-plane insertion operation while accommodating contacts arranged in three-dimensional space.
Data Source
AI summary
An electrical connector system includes a circuit card assembly and a pluggable module. The circuit card assembly including a host circuit board, a socket connector mounted to the host circuit board, and a guide rail extending along the host circuit board. The socket connector has a socket substrate having upper contacts having mating interfaces being accessible from above the socket connector and being coplanar. The guide rail has a guide feature and a module actuator. The pluggable module includes a module body operatively engaging the guide rail to guide mating of the module body with the guide rail in a module mating direction. The pluggable module includes an actuation feature engaging the module actuator to force mating of module contacts with the upper contacts in a contact mating direction transverse to the module mating direction.