Simulation-based design and optimization and fatigue characteristics for high-speed backplane connector

In high-speed interconnect systems, high-speed backplane connectors are widely utilized. Its mechanical reliability is related to the stability of entire application systems directly. Insertion-extraction force and fatigue characteristics are important factors that affect the reliability of high-speed backplane connectors. To enhance the reliability of high-speed backplane connectors, in this study, a single CAD/CAE parametric model of the contacts is established. Not only the dynamic analysis of the insertion and extraction process but also the electro-thermal-structure coupling of the contacts are carried out using finite element analysis. By changing the insertion position of male terminal, the length of female terminal, and the thickness of male terminal, the insertion-extraction force can be optimized. According to the simulation of the insertion-extraction force and the electric-thermal-structure coupling results, both the mechanical life of this connector and the thermal-mechanical fatigue life under electrifying condition are evaluated. The results show that the mechanical life and thermal-mechanical fatigue life were 376 cycles and 286 cycles, respectively. The design solutions can provide the reference for the structural design, optimization, and fatigue life prediction of high-speed backplane connector.