Electrical Contact Sleeve for Solder-Free RF Coaxial Grounding
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Solution Overview
Problem
In modern RF applications, providing reliable electrical connections between elements in RF systems, especially at high frequencies, is challenging due to the need for improved coupling of coaxial elements to circuitry, which often requires soldering, impeding easy replacement of defective parts.
Innovation Solution
An electrical contact sleeve with a circumferential conductor that couples to the outer conductor of a coaxial element and an electrical contact extending to a carrier substrate, allowing for secure electrical connections without soldering, enabling easy replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to couple the shielding conductor of a coaxial cable to the carrier substrate, then reliable electrical connection is achieved, but easy replacement of defective parts is impeded
Solution Approach 1:
The electrical contact sleeve is divided into functionally separate components: a circumferential conductor portion that couples to the coaxial outer conductor and contact portions that extend to the carrier substrate. This segmentation allows the contact sleeve to be replaced as a modular unit without requiring soldering, thus maintaining reliable electrical connections while enabling easy replacement of defective parts.
Solution Approach 2:
The electrical contact sleeve acts as an intermediary component between the coaxial cable's outer conductor and the carrier substrate's ground contacting surface. This intermediate element provides a reliable electrical connection through its conductive structure while being designed for tool-free installation and removal, solving the contradiction between connection reliability and replaceability.
2Reliability
If soldering is used to couple the shielding conductor to the carrier substrate, then secure electrical connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The invention replaces the soldering process (thermal/chemical joining method) with a mechanical insertion system. The contact sleeve is designed to be inserted into a recess and secured through mechanical interference fit or friction engagement, eliminating the need for soldering equipment and processes while maintaining secure electrical connections. This simplifies manufacturing by removing complex thermal processing steps.
3Reliability
If the circumferential conductor couples along a large section of the outer conductor circumference, then electrical connection reliability is improved, but the device complexity increases
Solution Approach 1:
The contact sleeve is designed to couple along a predetermined section of the outer conductor's circumference rather than requiring complete 360-degree contact. This partial action approach provides sufficient electrical connection reliability for RF signal transmission while keeping the structure simple and the manufacturing process straightforward, avoiding the complexity that would arise from designing for full circumferential engagement.
Data Source
AI summary
The present disclosure provides an electrical contact sleeve comprising a circumferential electrical conductor configured to couple to an outer conductor of an electrically conducting coaxial element at least along a predetermined section of the circumference of the outer conductor, and at least one electrical contact extending from the circumferential electrical conductor and comprising a contacting surface configured to contact an electrically conductive surface of a carrier substrate. In addition, the present disclosure provides a respective RF module and a respective method.