Tapered Electrical Terminal Mounting End for High Pin Density
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Solution Overview
Problem
Existing high-speed electrical connectors face challenges in achieving desired impedance levels and reducing cross-talk while maintaining mechanical integrity, particularly at the mounting ends of electrical terminals, which are often overlooked in design optimizations.
Innovation Solution
The electrical terminals have a mounting end that is substantially smaller than the mating end, featuring a compliant portion with a slit and tapered segments, allowing for reduced insertion forces and improved electrical performance, enabling insertion into micro via apertures without damage, and facilitating higher pin densities and reduced cross-talk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the spacing between electrical terminals is reduced to increase pin density, then the number of terminals per unit area increases, but impedance control and cross-talk reduction become more difficult
Solution Approach 1:
The patent applies local quality by creating a tapered mounting end with varying cross-sectional dimensions along its length. The insertion portion has a smaller cross-section than the base, allowing the terminal to fit into smaller apertures while maintaining proper electrical characteristics. This localized geometric modification enables improved impedance control in high-density configurations without compromising overall terminal performance
Solution Approach 2:
The patent changes the geometric parameters of the terminal mounting end by creating a tapered structure where the cross-sectional dimensions decrease from the base toward the insertion portion. This parameter change allows the terminal to adapt to smaller aperture sizes while maintaining electrical performance, enabling higher pin density without sacrificing impedance control
2Quantity of substance
If the terminal mounting end size is reduced to fit smaller apertures, then pin density increases, but mechanical strength and structural integrity may be compromised
Solution Approach 1:
The patent segments the terminal into distinct portions with different functions: a base portion providing structural strength and a tapered insertion portion providing fit into small apertures. This segmentation allows each portion to be optimized independently - the base maintains structural integrity while the insertion portion enables high pin density
Solution Approach 2:
The patent introduces a dimensional transition in the terminal structure by creating a tapered insertion portion that gradually reduces in cross-section. This dimensional change allows the terminal to fit into smaller apertures without compromising the structural integrity of the base portion, as the strength is concentrated in the larger base area while the reduced insertion portion provides the necessary fit
3Ease of manufacture
If traditional terminal designs are used with uniform cross-section, then manufacturing is simpler, but insertion forces are higher and electrical performance is degraded
Solution Approach 1:
The patent changes the cross-sectional parameters along the length of the insertion portion, creating a tapered structure that improves electrical performance by reducing capacitance and impedance discontinuities. While this adds some manufacturing complexity, the continuous taper can be achieved through standard forming processes, balancing manufacturing feasibility with electrical performance improvement
4Force
If the terminal insertion portion is made smaller for micro via applications, then insertion forces are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent creates a dynamic geometric transition in the insertion portion through the tapered structure. This gradual change in cross-section allows the terminal to progressively engage with the aperture walls during insertion, distributing the insertion force over a longer distance and reducing peak forces while maintaining precise alignment and fit
Data Source
AI summary
An electrical terminal of the type to be inserted into an aperture of an electrical panel member is provided. The electrical terminal may include a base, an insertion portion extending from the base to a first end, a slit formed through the insertion portion and defining a compliant portion having a first leg and a second leg. A segment of the first leg may be deformed in one direction, while a segment of the second leg may deformed in the opposite direction. Midpoints of each or both legs may be offset from the midpoint of the slit to achieve improved mechanical and electrical performance within a connector. Also provided is an electrical terminal having a tip that facilitates alignment with a panel member aperture and provides tactile feedback to a user, as well as an electrical terminal having a mounting end that is substantially smaller than its mating end, and connectors containing such terminals. Methods of routing electrical traces between adjacent electrical terminals are also provided.