Stacked Cassette for High-Density Cable Interconnects
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Solution Overview
Problem
Existing cable interconnect systems face challenges in providing high-density connections in limited spaces, with stacked jack connectors being complex to manufacture and interface connectors having reduced density due to bulky modular jacks and cable management issues.
Innovation Solution
A cassette design with a housing featuring stacked plug cavities and a contact subassembly with a circuit board and contacts of equal lengths, supported by shield elements for improved electrical performance, and rear mating connectors for high-density connections, allowing for efficient cable management and reduced signal degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If stacked jack connector assembly is used to increase connection density, then the number of receptacles per unit length is doubled, but the contact length varies between upper and lower rows causing signal degradation
Solution Approach 1:
The patent transitions from a planar arrangement of receptacles to a three-dimensional stacked configuration where contact sets are arranged in multiple rows (upper and lower) within the same footprint. This vertical stacking in another dimension doubles the connection density while maintaining consistent contact lengths through careful positioning of the circuit board and contact sets at equal distances from the mating interface.
Solution Approach 2:
The patent applies different contact lengths to different contact sets within the stacked assembly. Specifically, contact sets in the upper row have longer contacts than those in the lower row, with each contact length specifically designed to compensate for its position and achieve equal electrical characteristics. This local differentiation in contact geometry ensures uniform signal quality across all receptacles despite their different physical positions.
2Ease of repair
If individual modular jacks are mounted separately in interface connector, then each jack can be independently serviced, but the overall connection density is reduced due to bulky housing and cable management space requirements
Solution Approach 1:
The patent merges multiple individual modular jack functions into a single integrated stacked jack connector assembly. Multiple contact sets are mounted on a common circuit board within a shared housing, combining what would traditionally be separate modular jacks into one unified component. This integration achieves high connection density while maintaining the functional independence of each receptacle through separate contact sets that can be individually replaced.
Solution Approach 2:
The stacked jack connector assembly is designed with modular contact sets that can be independently replaced. Each contact set is a separate component mounted on the circuit board, allowing individual servicing of specific receptacles without affecting others. This segmentation enables ease of repair while the overall integrated structure maintains high connection density.
3Quantity of substance
If receptacles are arranged in stacked configuration to maximize space utilization, then connection density increases, but manufacturing complexity increases due to special housing features and contact length variations
Solution Approach 1:
The circuit board in the stacked jack connector assembly serves multiple functions simultaneously: it provides the structural mounting platform for all contact sets, establishes electrical connections between contact sets and the external interface, provides shielding between adjacent contact sets, and maintains precise positioning of contacts at equal distances from the mating interface. This multi-functionality reduces the need for separate specialized components and simplifies manufacturing.
Data Source
AI summary
A cassette includes a housing having a front and a rear. The housing has a plurality of plug cavities open at the front for receiving plugs therein, and the housing has a rear chamber open to the plug cavities. The cassette also includes a contact subassembly having a circuit board and a plurality of contacts arranged in contact sets coupled to the circuit board. Each contact set is configured to mate with a corresponding plug, where the contact subassembly is loaded into the rear chamber such that the contact sets are received in different corresponding plug cavities. The circuit board is oriented generally parallel to the front of the housing when the contact subassembly is loaded into the rear chamber.