PCB Connector Module for Pull-Resistant Diagnostic Data Links
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Solution Overview
Problem
Existing techniques for coupling high-speed data cables, such as ethernet cables, with vehicle diagnostic conductors are difficult, expensive, and prone to unintended disconnect, failing to withstand recommended pull forces in vehicular applications.
Innovation Solution
A connector module with a diagnostic header interface and high-speed data header interfaces, accessible via a housing, which includes a printed circuit board (PCB) that electrically couples the high-speed data header interfaces to ports of the diagnostic header interface, facilitating secure and efficient data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual splicing and soldering techniques are used to couple high-speed data cables with diagnostic conductors, then flexibility in connection methods is provided, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines multiple separate connection operations (splicing, soldering, terminal attachment) into a single integrated connector module. The PCB serves as a common platform that simultaneously provides mechanical support, electrical connection, and structural integrity, eliminating the need for separate manual assembly steps while maintaining connection flexibility.
Solution Approach 2:
The PCB acts as an intermediary component between the high-speed data cable and the diagnostic header interface. It provides a standardized intermediate platform that simplifies the connection process by offering pre-defined connection points and pathways, reducing the complexity of direct cable-to-conductor coupling.
2Adaptability or versatility
If manual splicing and soldering techniques are used to couple high-speed data cables with diagnostic conductors, then connection customization is enabled, but production cost and manufacturing difficulty increase
Solution Approach 1:
The connector module is pre-assembled with all necessary connections (data cable terminals, diagnostic header interfaces, and internal PCB traces) established before installation. This preliminary configuration allows for customization without requiring complex manual assembly during production, as the module can be manufactured once and then easily installed in various applications.
Solution Approach 2:
The system is divided into separate functional modules: the connector module with integrated PCB, the diagnostic header interface, and the high-speed data cable. This segmentation allows each component to be manufactured independently using optimized processes, reducing overall production cost while maintaining customization capability through modular assembly.
3Ease of operation
If traditional splicing and soldering connections are used, then connection flexibility is maintained, but connection reliability decreases due to unintended disconnect
Solution Approach 1:
Multiple connection functions are merged into the single connector module structure. The PCB provides both mechanical support and electrical connection simultaneously, creating a more reliable integrated solution compared to separate splicing and soldering operations. The unified structure reduces the number of potential failure points while maintaining installation flexibility.
4Object-affected harmful factors
If traditional connection methods with protective covers are used, then basic protection is provided, but durability against pull force is insufficient
Solution Approach 1:
The connector module employs a composite construction combining rigid PCB material with reinforced housing structure. This composite design provides both basic protection and enhanced mechanical strength to withstand pull forces, overcoming the limitations of simple protective covers while maintaining connection accessibility.
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3A~3B
AI summary
A connector module is described that includes a diagnostic header interface configured to be accessible via a housing. The connector modules also includes at least one high speed data header interface configured to be accessible via the housing. The connector module also includes a printed circuit board (PCB) within the housing, the PCB includes at least one electrical conductor that electrically couples the high speed data header interface to at least one port of the diagnostic header interface.