Angled Mini-Coaxial Automotive Connector with Dielectric Insulation
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Solution Overview
Problem
Existing connectors for automotive applications face challenges in ensuring safe, reliable transmission of high-frequency signals while being compact and durable, with complex manufacturing processes and the need for standardized solutions like FAKRA connectors, which require efficient production methods to maintain quality and reduce complexity.
Innovation Solution
A mini-coax automotive connector design featuring a housing body with a coax plug connector having angled electrically conductive inner contacts limited by dielectric insulation elements, reducing component complexity and facilitating easy assembly through injection molding and embossing processes, allowing for flexible orientation and secure connection to printed circuit boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the inner contact is angled to connect the coax socket to the printed circuit board, then the connector can be connected in non-perpendicular orientations, but the manufacturing complexity increases due to the need for precise angling
Solution Approach 1:
The dielectric insulation elements are pre-formed with integrated angling surfaces before assembly. The inner contact is inserted into these pre-formed elements, which automatically provide the predetermined angle without requiring complex angling operations during assembly. This preliminary preparation of the insulation elements eliminates the need for complex angling mechanisms.
Solution Approach 2:
The dielectric insulation elements serve as intermediary components between the inner contact and the housing body. These intermediaries not only provide electrical insulation but also incorporate angling surfaces that automatically angle the inner contact to the predetermined angle. This intermediary structure simplifies the overall design by combining multiple functions (insulation, angling, positioning) into a single component.
2Manufacturing precision
If multiple components are used in the connector assembly, then the connector can be manufactured with consistent quality, but the production time increases
Solution Approach 1:
The dielectric insulation elements are combined with the angling function in a single integrated component. The injection molding process creates the insulation element with built-in angling surfaces, eliminating the need for separate angling mechanisms or multiple assembly steps. This merging of functions maintains quality consistency while reducing production time.
Solution Approach 2:
The dielectric insulation elements are designed to self-angle the inner contact during insertion. The angling surfaces of the insulation elements automatically guide and angle the inner contact to the predetermined angle without requiring external angling devices or complex assembly operations. This self-service mechanism simplifies assembly and increases production speed.
3Adaptability or versatility
If the inner contact is made thicker to provide sufficient material for angling, then the angling can be achieved, but the connector dimensions increase and compactness is reduced
Solution Approach 1:
The inner contact is designed as a thin, flat strip that is flexible enough to be angled. The dielectric insulation elements provide the structural support and angling surfaces, allowing the thin inner contact to achieve the predetermined angle without requiring increased thickness. This approach maintains connector compactness while enabling the necessary angling capability.
Data Source
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AI summary
One aspect relates to a connector (10), in particular a mini-coaxial automotive connector, for connecting to a compatible plug device, comprising: a housing body (12) and a coaxial connector (20) for connecting to a corresponding coaxial socket of the compatible plug device, wherein the coaxial connector (20) extends from the housing body (12) in a connection direction (V) and is arranged at least partially in the housing body (12), wherein the coaxial connector (20) comprises: an electrically conductive sleeve (54), an electrically conductive inner contact (42) with a first contact section (44) which is angled relative to a second contact section (46) of the inner contact (42) at a predetermined angle, wherein the first contact section (44) is arranged at least partially in the sleeve (54) and the second contact section (46) is connectable to a printed circuit board.a first dielectric insulating element (48) which surrounds at least partially the first contact section (44) and is arranged at least partially in the sleeve (54), and a second dielectric insulating element (50) which surrounds at least partially the second contact section (46), wherein the first dielectric insulating element (48) and the second dielectric insulating element (50) are arranged on the inner contact (42) such that the angling of the first contact section (44) relative to the second contact section (46) is limited to the predetermined angle.