High-Density Connector Shielding With Welded Tabs for Crosstalk

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Solution Overview

Problem

Current electrical connectors face challenges in handling high-speed, high-density data transmission due to increased electrical interference and crosstalk, particularly at frequencies above 112 Gbps, where existing shielding and material configurations are inadequate.

Innovation Solution

The design incorporates conductive elements with first and second shielding members on opposite sides of the assembly housing, with tabs connected to ground conductors via beams and slots, and lossy material coupling to reduce crosstalk and enhance high-frequency performance by shielding throughout the signal path.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If electrical conductors are placed close together to increase density, then the connector achieves high density, but electrical interference and crosstalk between adjacent signal conductors increases

Engineering Contradiction:

Improveconductor densityVSAvoidelectrical interference and crosstalk

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

A shielding member is introduced as an intermediary element between adjacent signal conductors. The shielding member includes a body with multiple tabs that are electrically connected to ground conductors, creating an electromagnetic barrier that prevents crosstalk while allowing the conductors to remain in close proximity for high density

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The shielding member changes the electromagnetic parameters of the conductor environment by providing controlled impedance pathways through its tabs connected to ground conductors. This modifies the electromagnetic field distribution to reduce interference while maintaining signal integrity

Inventive Principle:

Principle #35Parameter changes

2Reliability

If shield members are added between signal conductors to reduce crosstalk, then electrical performance improves, but device complexity increases

Engineering Contradiction:

Improveelectrical performance and crosstalk reductionVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shielding member is merged with the ground conductor structure through electrical connection via tabs. This integration allows the shielding function to be achieved without adding completely separate components, thereby reducing overall device complexity while maintaining crosstalk protection

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The shielding member serves multiple functions simultaneously: it provides electromagnetic shielding between signal conductors, maintains mechanical spacing, and electrically connects to ground conductors through its tabs. This multi-functionality reduces the need for separate components

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple shielding members are placed on opposite sides of the assembly housing, then crosstalk reduction is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvecrosstalk reductionVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The shielding protection is segmented into multiple independent shielding members positioned on opposite sides of the assembly housing. Each shielding member can be manufactured and positioned separately, allowing for modular assembly while achieving comprehensive crosstalk reduction from multiple directions

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration significantly improves near-end and far-end crosstalk by about 5 dB across a wide frequency range, enabling reliable high-speed data transmission above 112 Gbps by effectively reducing electromagnetic interference.

Implementation Method 1

shielding members are often placed between or around adjacent signal conductors. The shields may prevent signals carried on one conductor from creating 'crosstalk' on another conductor

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 2

lossy material coupling to reduce crosstalk and enhance high-frequency performance by shielding throughout the signal path

Methodology Applied

Scientific EffectElectromagnetic absorption: Absorption (EM radiation)

Data Source

PatentUS20240332867A1High speed, high density connector

Publication Date: 2024.10.03 FCI USA LLC

AI summary

Electrical connectors for very high speed signals at frequencies to support high data rates, including at or above 112 Gbps. A connector includes lead assemblies, each of which includes conductors held by an assembly housing, and shielding members disposed on opposite sides of the assembly housing. Each conductor has a mating end and a mounting end opposite the mating end. The shielding members have tabs disposed on the mating ends of ground conductors from the opposite sides. The tabs on the opposite sides can be welded to respective ground conductors simultaneously. The tabs are connected to bodies of respective shielding members by beams separated by slots. The slots are sized to both provide tolerances for welding and to reduce crosstalk further. The shielding members alternatively or additionally can have tabs disposed on the mounting ends of the ground conductors from the opposite sides.