Shielded Four-Layer Connector Assembly for PCB-to-Wire Integration
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Solution Overview
Problem
Existing electrical connector assemblies for printed circuit boards face challenges in effectively connecting side-band and differential-pair contacts to both the board and wires, requiring improved mechanical and electrical integration.
Innovation Solution
A hybrid four-layer contact module with insulative housing and stacked units, featuring side-band and differential-pair contacts, spacers, grooves, and metallic shields for secure mounting and grounding, ensuring reliable electrical connections between the printed circuit board and wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hybrid four-layer contact module with stacked units is used to connect both side-band and differential-pair contacts, then the mechanical and electrical integration is improved, but the device complexity increases
Solution Approach 1:
The contact module is divided into multiple stacked units (first unit, second unit, third unit, fourth unit), each handling specific contact types. This segmentation allows complex functionality to be distributed across simpler modular components, improving integration reliability while managing complexity through standardization of repeating units.
Solution Approach 2:
The patent implements a nested structure where multiple contact units are stacked within a single housing, with each unit containing insulative bodies and contacts nested within designated spaces. The upper and lower units are nested vertically, creating a compact four-layer configuration that integrates multiple contact types in a unified structure.
2Ease of operation
If spacers are added to the tail sections of side-band contacts for correct mounting, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
Spacers are pre-installed on the tail sections of side-band contacts during the manufacturing process. This preliminary action ensures correct mounting alignment is built into the component itself, eliminating the need for complex external alignment mechanisms or complex assembly procedures during installation.
3Ease of manufacture
If grooves are formed in the side sector to receive differential-pair contacts and wires, then the ease of manufacture is improved, but the structural integrity may be reduced
Solution Approach 1:
Grooves are formed only in the side sector of the insulative body where wire reception is required, rather than throughout the entire structure. This localized modification provides the necessary ease of manufacture for wire insertion while preserving the structural integrity of the main insulative body, as the grooves are confined to non-critical regions.
Data Source
AI summary
An electrical connector assembly includes a contact module having an upper part and a lower part stacked with each other. The upper part includes a front/outer upper unit and a rear/inner upper unit and the lower part includes a front/outer lower unit and a rear/inner lower unit. Each unit includes an insulative body and a plurality of contacts integrally formed with the insulative body via an insert-molding process. The insulative body includes a middle sector and a pair of side sectors. The contacts include side-band contacts retained in the middle sector and differential-pair contacts retained in the side sectors.