Segmented Contact Insulator Assembly for Stable Differential Pair Contacts
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Solution Overview
Problem
Existing contact insulators for high-speed connectors fail to securely hold contacts, especially those attached to stiff or twisted conductors, and often dislodge during assembly due to movements required for positioning additional contacts.
Innovation Solution
The use of segmented contact insulators with retention projections and access openings allows for secure insertion and retention of contacts, reducing assembly complexity and time by enabling controlled manipulation of signal conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all contacts are held in a single insulator housing, then the housing structure is simplified, but the contacts and conductors dislodge during assembly due to required movements for positioning
Solution Approach 1:
The patent divides the insulator housing into multiple segments or sections, each capable of independently holding contacts. This segmentation allows contacts to be positioned and secured in separate compartments, preventing dislodging during assembly operations on other contacts while maintaining a manageable overall structure.
2Reliability
If contacts are securely retained in the insulator, then contact positioning stability is improved, but assembly complexity increases due to retention mechanisms
Solution Approach 1:
The insulator housing incorporates self-retaining features such as friction fits, elastic deformation of contact receptacles, or snap-fit mechanisms that automatically secure contacts during insertion without requiring additional active retention components. The structure itself provides the retention function, eliminating the need for separate complex retention mechanisms.
Data Source
Figure 1~2
Figure 3
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AI summary
A contact insulator (65) for use with high speed cable (60) with differential pairs of contacts (63). A contact receiving portion (66) has contact receiving slots (74) which open from a side (73) of the contact insulator (65). A conductor receiving portion (68) has conductor receiving slots (79) which open from an opposite side (78) of the contact insulator (65). A transition portion (70) is positioned between the contact receiving portion (66) and the conductor receiving portion (68). The transition portion (70) has a contact receiving opening (82) which extends through the contact insulator (65). The contact receiving opening (82) is dimensioned to allow the contacts (63) to be inserted therethrough. The contact insulator (65) is rotated about the contacts (63) and signal conductors (61) to position the contacts (63) in the contact receiving slots (74) through the side (73) of the contact insulator (65) and position the signal conductors (61) in the conductor receiving slots (79) through the opposite side (78) of the contact insulator (65).