Segmented Contact Insulators for Stable Differential Pair Termination
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Solution Overview
Problem
Existing contact insulators for high-speed connectors face challenges in securely positioning differential pairs of contacts without dislodging already seated contacts, especially when dealing with stiff or twisted conductors like Cat6a cables.
Innovation Solution
The development of segmented contact insulators with a contact receiving portion and a conductor receiving portion, connected by a transition portion, allows for secure insertion and positioning of contacts and conductors. This design enables easy assembly and disassembly without damaging the contacts or insulators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single insulator housing is used to hold all contacts, then the connector assembly is simpler in structure, but the contacts and conductors become dislodged during assembly and reorganization
Solution Approach 1:
The insulator housing is divided into multiple segments, each capable of independently holding a subset of contacts. This segmentation allows contacts to be securely positioned in smaller groups, preventing dislodging while maintaining overall structural simplicity through modular design.
2Productivity
If all contacts are inserted into the insulator housing simultaneously, then assembly is faster, but contacts attached to stiff or twisted conductors cannot be properly positioned
Solution Approach 1:
The insulator housing segments enable contacts to be inserted in smaller batches rather than all at once. Each segment can be filled and secured independently, making it easier to handle stiff or twisted conductors while maintaining reasonable assembly speed through the modular approach.
Solution Approach 2:
Contacts can be pre-positioned in the insulator segments before final assembly into the connector housing. This preliminary positioning allows proper alignment and securing of contacts with stiff conductors before the complete assembly is finalized, improving ease of operation.
3Ease of operation
If the insulator housing is rotated to access different sides for contact positioning, then all contacts can be positioned, but already seated contacts become dislodged
Solution Approach 1:
By dividing the insulator housing into segments that can be independently accessed or removed, the design allows contact positioning on different sides without rotating the entire housing. Each segment can be accessed separately, maintaining the stability of already seated contacts in other segments.
4Reliability
If contacts are securely held in the insulator housing, then contact positioning is stable, but reorganization of contacts for correct signal pair orientation becomes difficult
Solution Approach 1:
The segmented insulator housing allows individual segments to be removed and repositioned to reorganize contacts for correct signal pair orientation. Contacts within each segment remain securely held, but the modular segment structure enables easy reconfiguration without damaging contacts or the insulator.
Data Source
AI summary
A contact insulator for use with high speed cable with differential pairs of contacts. A contact receiving portion has contact receiving slots which open from a first side of the contact insulator. A conductor receiving portion has conductor receiving slots which open from a second side of the contact insulator. A transition portion is positioned between the contact receiving portion and the conductor receiving portion. The transition portion has a contact receiving opening which extends through the contact insulator. The contact receiving opening is dimensioned to allow the contacts to be inserted therethrough. The contact insulator is rotated about the contacts and signal conductors of the high speed cable to position the contacts in the contact receiving slots through the first side of the contact insulator and position the signal conductor in the conductor receiving slots through the second side of the contact insulator.