Connector Insert Structure to Prevent Basket Finger Deformation
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Solution Overview
Problem
Telecommunications connectors, such as 4.3-10 connectors, are prone to damage and improper connections due to geometric similarities with other types of connectors, leading to costly equipment failures when Linemen attempt to connect incompatible components, especially the Mini-Din connector, which can cause plastic deformation and damage to the outer conductor basket.
Innovation Solution
A protective insert is placed between the inner conductor socket and the outer conductor basket, featuring a corrugated, pedal-shaped structure with engagement and stiffening sections that prevent plastic deformation of the axially projecting fingers by inhibiting the insertion of non-mating connectors and ensuring proper alignment, thus maintaining the elastic properties of the basket fingers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective insert is added to prevent damage to outer conductor basket fingers, then reliability is improved, but device complexity increases
Solution Approach 1:
A protective insert is introduced as an intermediary component between the inner conductor socket and outer conductor basket. This insert features a corrugated pedal-shaped structure with engagement sections that interact with the basket fingers, preventing them from being forced outward by incompatible connectors while maintaining proper electrical connectivity for mating connectors.
Solution Approach 2:
The protective insert is divided into multiple functional segments: engagement sections that interface with individual basket fingers, stiffening sections that provide structural support, and a corrugated body that allows controlled deformation. This segmentation enables each part to perform its specific protective function independently.
2Strength
If the outer conductor basket fingers are made more robust to resist deformation, then strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
Instead of making the entire outer conductor basket more robust, the protective insert provides localized reinforcement only where needed - at the engagement sections that interface with vulnerable basket fingers. The insert's corrugated structure offers high stiffness-to-weight ratio, providing local strength without requiring thick-walled or overly robust basket construction.
Solution Approach 2:
The protective insert combines multiple material properties within a single component: the corrugated structure provides both flexibility for mating operations and stiffness for protection, while the integrated design combines structural support and electrical isolation functions in one element, simplifying the overall manufacturing process.
3Ease of manufacture
If the connector structure is simplified to reduce cost, then ease of manufacture is improved, but reliability deteriorates
Solution Approach 1:
The protective insert serves multiple functions simultaneously: it protects basket fingers from deformation by incompatible connectors, provides structural support to the inner conductor socket, maintains proper alignment during mating operations, and prevents direct contact between the outer conductor basket and incompatible connectors. This multi-functionality reduces the need for additional separate protective components.
4Ease of operation
If the basket fingers are made more flexible to ensure proper connection, then ease of operation is improved, but object-affected harmful factors worsen
Solution Approach 1:
The protective insert is installed beforehand to cushion and absorb the harmful forces generated by incompatible connectors before they can reach and damage the basket fingers. The corrugated structure of the insert allows it to deform elastically during improper insertion attempts, preventing force transmission to the vulnerable basket fingers while still permitting proper mating operations.
Data Source
AI summary
A connector, and connector insert, configured to inhibit plastic deformation of at least one of the axially projecting fingers of an outer conductor basket associated with a connector. The connector insert comprises: (i) an outwardly facing flange configured to engage a shoulder formed at a base of the axially projecting fingers of the outer conductor basket, (ii) a tubular structure defining an elongate axis and having plurality of engagement sections extending normal to the outwardly facing flange, each engagement section having a surface disposed substantially normally to a radial projecting from the elongate axis; and (iii) a plurality of stiffening sections having a surface disposed substantially parallel to a radial projecting from the elongate axis. The engagement sections function to prevent plastic deformation of the axially projecting fingers, thereby preventing damage to the fingers and/or the transmission of RF signals The stiffening sections function to support the engagement sections while furthermore preventing the insertion of a non-mating second connector into, or against, the outer conductor basket of a first connector.