Coaxial Connector Shell Alignment to Prevent Contact Buckling
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Solution Overview
Problem
Existing multiple coaxial connector systems are inadequate in correcting tilt and shaft misalignment during fitting, leading to increased force on contacts and potential buckling.
Innovation Solution
A multiple coaxial connector system with a receptacle shell that includes a tapered guide hole and an accommodation portion, where the insertion-direction length of the guide hole and accommodation portion are designed to correct misalignment before full fitting, allowing for reduced insertion force and preventing contact buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector fitting mechanism is used, then the structure is simple, but tilt and shaft misalignment cannot be corrected leading to contact buckling
Solution Approach 1:
The connector structure is segmented into multiple functional components: a housing, a receptacle with a tapered guide hole, and an accommodation portion. This segmentation allows each component to perform a specific function - the guide hole corrects tilt, the accommodation portion corrects shaft misalignment, and the contact elements establish electrical connection. By dividing the connector into these specialized segments, reliable alignment is achieved without requiring an overly complex monolithic structure.
Solution Approach 2:
The tapered guide hole performs preliminary alignment action before the main contact engagement. As the plug is inserted, the guide hole first corrects tilt misalignment by guiding the plug shells into proper orientation. The accommodation portion then performs preliminary shaft misalignment correction before the contacts fully engage. This preliminary alignment action prevents buckling during final contact engagement by ensuring proper positioning is established in advance.
2Reliability
If tilt and shaft misalignment correction is added, then contact buckling is prevented, but insertion force increases
Solution Approach 1:
The alignment correction actions are performed preliminarily during the insertion process itself, rather than requiring additional force after contact engagement. The tapered guide hole gradually corrects tilt as the plug enters, and the accommodation portion gradually corrects shaft misalignment before full contact engagement. This distributes the correction force over the insertion distance, preventing sudden force spikes that would increase peak insertion force.
Solution Approach 2:
The geometry parameters of the guide hole and accommodation portion are specifically designed to optimize the alignment correction process. The taper angle of the guide hole and the dimensions of the accommodation portion are controlled within specific ranges to ensure smooth alignment without excessive friction or resistance. By carefully controlling these geometric parameters, the insertion force is minimized while still achieving effective tilt and shaft misalignment correction.
3Manufacturing precision
If the guide hole and accommodation portion are designed for alignment correction, then misalignment is reduced, but manufacturing complexity increases
Solution Approach 1:
The guide hole and accommodation portion are merged into a single integrated receptacle shell structure rather than being separate components. This merging reduces the total number of parts that need to be manufactured and assembled. The receptacle shell is formed as a single piece with the tapered guide hole and accommodation portion built-in, simplifying the manufacturing process while maintaining the alignment correction functionality. This integration approach achieves high alignment accuracy without proportionally increasing manufacturing complexity.
Solution Approach 2:
The geometric parameters of the guide hole (taper angle, length) and accommodation portion (size, shape) are optimized to balance manufacturing ease with alignment precision. By selecting appropriate parameter ranges, the components can be manufactured using standard machining processes without requiring ultra-precision equipment, while still achieving the necessary alignment accuracy to prevent contact buckling during assembly.
Data Source
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AI summary
A plug includes a housing, a plurality of plug shells that are accommodated in the housing in a manner to protrude from the housing by a predetermined length A, a plurality of plug bodies that are accommodated in the plug shells respectively, and a plurality of plug contacts that are fixed to the plug bodies respectively. A receptacle includes a receptacle shell, a receptacle body, and a receptacle contact. The receptacle shell includes: an accommodation portion that entirely accommodates ends of the plurality of plug shells protruding from the housing, and whose insertion-direction length B satisfies B < A.