Receptacle Assembly Embossment Alignment for High Density Connectors

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Solution Overview

Problem

Existing electrical connectors face issues with signal loss and degradation due to cross-talk, misalignment during assembly, and insufficient performance and density, leading to potential damage and failure.

Innovation Solution

A receptacle assembly with a front housing featuring embossed conductive holders and comb-like separating walls for precise alignment of contact modules, along with ribbed contact channels for secure mating, providing improved alignment and shielding to address these issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If contact modules are stacked into housing to increase connector density, then connector density increases, but alignment difficulty increases causing damage to contacts

Engineering Contradiction:

Improveconnector densityVSAvoidalignment precision

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

Alignment features (protrusions on contact modules, corresponding recesses in housing) are designed and positioned in advance to guide proper alignment during the stacking process, preventing misalignment before damage can occur

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Alignment features act as intermediary elements between the contact modules and housing, facilitating proper positioning and reducing direct contact stress that could cause damage during assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If contact modules are stacked into housing to increase connector density, then connector density increases, but assembly difficulty increases

Engineering Contradiction:

Improveconnector densityVSAvoidassembly ease

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

Alignment features are pre-configured on both the contact modules and housing to automatically guide proper positioning during assembly, eliminating the need for complex alignment procedures

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The contact modules are designed as separate, modular units with integrated alignment features, allowing them to be independently manufactured and then easily assembled into the housing through straightforward stacking

Inventive Principle:

Principle #1Segmentation

3Quantity of substance

If electrical connectors are placed in close proximity to increase density, then connector density increases, but cross talk increases causing signal loss

Engineering Contradiction:

Improveconnector densityVSAvoidcross talk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

Ground shields are extracted and positioned between adjacent signal contacts to create electromagnetic isolation, removing the harmful electromagnetic coupling that causes cross talk while maintaining compact connector spacing

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS8475209B1Receptacle assembly

Publication Date: 2013.07.02 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A receptacle assembly includes a front housing having a mating end and a loading end. The front housing has pockets at the loading end separated by separating walls having slots therethrough open at rears thereof. The front housing receives contact modules in corresponding pockets each having a holder holding a plurality of contacts between first and second side walls. The holders have embossments extending from the first side walls proximate to the fronts of the holders. The embossments are loaded into corresponding slots through the rears of the separating walls to control positions of the contact modules with respect to the front housing.