Programmable Lead Frame for Electrical Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of electrical connectors with different terminal configurations is challenging due to the need for distinct lead frames, increasing complexity and cost.
Innovation Solution
The use of a housing with first and second contact module assemblies, each featuring a lead frame with commoning members that can be configured with different patterns of tabs to electrically common selected terminals, allowing for programmable wiring patterns without requiring separate lead frames for each configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different lead frames are designed and manufactured for each contact module having different terminal and/or contact patterns, then the electrical performance is improved by reducing crosstalk, but the manufacturing difficulty and cost increase
Solution Approach 1:
A single programmable lead frame structure is designed to serve multiple functions by accommodating different terminal and contact patterns through reconfigurable connections. The lead frame includes a body with multiple contact elements that can be electrically connected to different terminals based on programming, allowing one physical structure to replace multiple specialized lead frames while maintaining the ability to reduce crosstalk through optimized patterns.
Solution Approach 2:
The lead frame incorporates programmable connectivity that allows the electrical connections to be dynamically configured after manufacturing. This enables the same physical lead frame to be adapted for different terminal patterns and contact configurations, providing the flexibility previously requiring multiple static lead frame designs while simplifying manufacturing.
2Reliability
If different lead frames are designed and manufactured for each contact module having different terminal and/or contact patterns, then the electrical performance is improved by reducing crosstalk, but the manufacturing cost increases
Solution Approach 1:
A single programmable lead frame structure is designed to serve multiple functions by accommodating different terminal and contact patterns through reconfigurable connections. The lead frame includes a body with multiple contact elements that can be electrically connected to different terminals based on programming, allowing one physical structure to replace multiple specialized lead frames while maintaining the ability to reduce crosstalk through optimized patterns.
3Ease of manufacture
If a single lead frame is used for all contact modules, then the manufacturing complexity is reduced, but the ability to reduce crosstalk between adjacent contact modules is lost
Solution Approach 1:
The lead frame incorporates programmable connectivity that allows the electrical connections to be dynamically configured after manufacturing. This enables the same physical lead frame to be adapted for different terminal patterns and contact configurations, providing the flexibility previously requiring multiple static lead frame designs while simplifying manufacturing.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector comprises a housing and first and second contact module assemblies held by the housing. Each of the contact module assemblies comprises a lead frame having a plurality of terminals (116). The first contact module assembly (50A) comprises a first commoning member (124) at least partially comprising an electrically conductive material. The first commoning member (124) has a plurality of first tabs (122) that are electrically connected to selected ones of the terminals (116a) of the first contact module assembly (50A), thereby electrically commoning the selected ones (116a) of the terminals of the first contact module assembly (50A). The first tabs (122) are arranged to configure the lead frame (100A) of the first contact module assembly (50A) with a first pattern (144) of commoned terminals (116a). The second contact module assembly comprises a second commoning member at least partially comprising an electrically conductive material. The second commoning member has a plurality of second tabs that are electrically connected to selected ones of the terminals of the second contact module assembly, thereby electrically commoning the selected ones of the terminals of the second contact module assembly. The second tabs are arranged to configure the lead frame of the second contact module assembly with a second pattern of commoned terminals that is different from the first pattern (144).