Symmetric Header Connector for High-Vibration Backplanes
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Solution Overview
Problem
Existing backplane connector systems are limited in ruggedness and signal integrity, particularly in high shock and vibration environments, and lack protection against electrostatic discharge, which can compromise digital signal security.
Innovation Solution
The development of a connector system with interchangeable modules offering varying degrees of ruggedness and electrical performance, including plastic, shielded, and rugged connectors, featuring metal shielding and machined metal frames for enhanced durability and signal integrity, and allowing for flexible orientation and mounting configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional plastic connector housing is used, then manufacturing cost is reduced, but protection from electrostatic discharge and shielding benefits are limited
Solution Approach 1:
The connector housing combines plastic and metal materials to achieve both cost-effectiveness and enhanced protection. The plastic housing provides structural support and cost benefits, while integrated metal shielding elements provide electrostatic discharge protection and electromagnetic interference shielding, resolving the contradiction between protection level and device complexity.
2Reliability
If keying features are provided to maintain signal integrity, then connector orientation is constrained, but manufacturing complexity increases with multiple connector housings
Solution Approach 1:
The connector housing is designed with symmetric contact channel arrangements that allow the same housing design to be used for multiple connector orientations and configurations. This universal design maintains signal integrity through proper contact alignment while reducing the number of unique housing variants needed, thereby reducing manufacturing complexity.
3Ease of manufacture
If signal contacts provide mating spring contact to limited sides, then manufacturing is simplified, but ruggedness in high shock and vibration environments deteriorates
Solution Approach 1:
The contact structure incorporates localized reinforcement features at critical mating surfaces while maintaining overall manufacturing simplicity. The spring contact mechanism is enhanced with additional contact surfaces and reinforced mounting structures in areas subject to shock and vibration, providing targeted improvement in ruggedness without completely redesigning the entire contact structure.
4Adaptability or versatility
If connector interface is designed for controlled office environments, then manufacturing cost is reduced, but capability to withstand high shock and vibration environments is limited
Solution Approach 1:
The connector interface incorporates dynamic elements such as spring-loaded contacts and flexible mounting structures that adapt to environmental conditions. These dynamic features allow the connector to maintain reliable electrical connection and mechanical integrity across a wider range of environmental conditions including shock and vibration, while adding minimal complexity to the overall interface structure.
Data Source
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AI summary
A header connector (310) includes socket contacts (322) having a socket portion extending along a longitudinal axis that defines a reception area configured to receive a mating contact. A housing (320) extends along a central axis between mating and mounting ends (314, 312) and has contact channels open between the mating and mounting ends that receive the socket contacts (322). The housing has a primary plane and a secondary plane with the contact channels being arranged symmetrically about the primary plane and the secondary plane such that the housing is configured to be mated with a receptacle connector in a first orientation and a second orientation different than the first orientation.