Connector Assembly Overmolded Cavity Insert
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Solution Overview
Problem
The durability of plastic carrier strips used in manufacturing RF connector assemblies is compromised by repeated reeling and un-reeling, and the limited dimensions of cavity inserts hinder their proper fitting around outer contacts, leading to loading issues.
Innovation Solution
The connector assembly features an overmolded cavity insert that surrounds the middle segment of the outer contact, with an interior surface engaging the exterior surface and following its contours, eliminating the need for a plastic carrier strip and ensuring proper fitment by being formed in situ on the outer contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cavity inserts are molded on a plastic carrier strip and repeatedly reeled and un-reeled for assembly, then the cavity inserts can be packaged and transported efficiently, but the plastic carrier strip durability deteriorates and breaks easily
Solution Approach 1:
The invention extracts the cavity insert from the plastic carrier strip by providing it as a separate component. The cavity insert is inserted into the outer housing cavity independently, eliminating the need for plastic carrier strips and their associated reeling operations that cause durability issues.
Solution Approach 2:
The invention eliminates the use of disposable plastic carrier strips entirely by providing a metal cavity insert that is permanently installed in the outer housing. This replaces the temporary, fragile plastic carrier strip with a durable, long-lasting metal component.
2Manufacturing precision
If cavity inserts are made with strictly limited dimensions to fit within outer housing cavities, then they can be installed in standard housings, but they cannot fit over outer contacts with varying diameters
Solution Approach 1:
The invention segments the connector assembly into distinct components: the outer contact, the cavity insert, and the outer housing. The cavity insert is designed with specific dimensions to fit within the housing cavity, while the outer contact maintains its own dimensional specifications. This segmentation allows each component to be optimized independently, enabling the outer contact to have varying diameters while the cavity insert maintains consistent dimensions for proper fitting.
Solution Approach 2:
The cavity insert acts as an intermediary component between the outer contact and the outer housing. It provides a standardized interface that accommodates the outer contact while fitting within the housing cavity, thereby enabling compatibility across different connector configurations without compromising dimensional precision.
3Ease of manufacture
If the carrier strip fixes at least one end of the outer contact, then the outer contact can be held during manufacturing, but the carrier strip blocks the cavity insert from being loaded onto the outer contact
Solution Approach 1:
The invention extracts the cavity insert loading operation from the constraints imposed by the carrier strip. By providing the cavity insert as a separate component that is inserted into the outer housing cavity rather than being loaded onto the outer contact, the carrier strip no longer blocks the loading operation. The cavity insert bypasses the carrier strip entirely, enabling easy loading without interference.
Solution Approach 2:
The invention eliminates the need for the carrier strip to serve as a loading pathway for the cavity insert. The carrier strip's temporary holding function during manufacturing is sufficient, and the permanent installation of the metal cavity insert removes any ongoing interference, effectively discarding the carrier strip's restrictive role after initial manufacturing.
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 solution enhances the durability of the connector assembly by eliminating the fragility of plastic carrier strips and ensures precise fitting of the cavity insert around the outer contact, improving assembly efficiency and reliability.
Implementation Method 1
The cavity insert has an overmold body. An interior surface of the overmold body engages an exterior surface of the outer contact and follows contours of the exterior surface along the middle segment.
Data Source
AI summary
A connector assembly includes an outer contact and a cavity insert. The outer contact has a mating segment, a terminating segment, and a middle segment therebetween. The mating segment is configured to engage a mating outer contact of a mating connector assembly. The terminating segment is configured to be terminated to a cable. The cavity insert surrounds the middle segment of the outer contact. The cavity insert has an overmold body. An interior surface of the overmold body engages an exterior surface of the outer contact and follows contours of the exterior surface along the middle segment.