Curved Metal Connector Shell for Stable RF Signal Transmission
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Solution Overview
Problem
Existing connector designs face challenges with increased complexity, material waste, and RF performance issues, particularly in angled connectors like 90° header connectors, leading to signal degradation and manufacturing inefficiencies.
Innovation Solution
A curved metal tube is used as the connector shell, manufactured through processes like extrusion, stamping, and deep drawing, followed by bending, to ensure consistent impedance and reduced material waste, with optional die casting for intricate designs, and a method involving conductor and dielectric insulator insertion to form the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex multi-part die-cast housings are used to address angled connector issues, then the connector can accommodate angled data channels, but the manufacturing complexity and assembly complexity increase
Solution Approach 1:
The patent merges the housing structure into a single curved metal tube that integrates multiple functions (shielding, structural support, angular positioning) that were previously distributed across multiple die-cast parts. This consolidation reduces the number of components and simplifies manufacturing while maintaining the angled connector functionality.
Solution Approach 2:
The patent employs a curved metal tube with a specific curvature radius to achieve the desired angular orientation. The curvature allows the connector to bend at the required angle while maintaining a consistent cross-section, enabling angled data channel accommodation without complex multi-part constructions.
2Ease of manufacture
If traditional die-cast housing processes are used, then connectors can be manufactured, but material waste increases and manufacturing costs rise
Solution Approach 1:
The patent changes the manufacturing approach from subtractive die-casting to a formative process (curving a metal tube), which preserves material and reduces waste. The consistent cross-section of the tube allows for efficient material utilization while achieving the desired connector geometry.
3Ease of manufacture
If the metal tube cross-section varies along its length, then the tube can be formed, but impedance consistency deteriorates and RF performance decreases
Solution Approach 1:
The patent uses a curved metal tube with a consistent cross-section throughout its length. The curvature is achieved through controlled forming processes that maintain the cross-sectional dimensions, ensuring impedance consistency while allowing the tube to bend to the required angle for connector application.
4Adaptability or versatility
If complex multi-part housings are used, then angled connections can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent combines multiple manufacturing operations into a streamlined process for forming the curved metal tube. The single-piece construction eliminates the need for assembling multiple parts, reducing production time and increasing manufacturing efficiency while maintaining angled connection capability.
Data Source
Figure 1a~1b
Figure 2~3
Figure 4~5
AI summary
The present invention is directed to an metal shell (2) for a connector (1) for connecting two electrical components, said metal shell (2) being adapted to be connected at one end (2a) to a first electrical component and at the other end (2b) to a second electrical component, wherein the metal shell (2) is a metal tube (10) which is curved along its longitudinal direction. The present invention is also directed to manufacturing methods for manufacturing a connector (1) connecting two electrical components. With such a metal shell (2) for a connector (1) for connecting two electrical components and with such manufacturing methods, the present invention makes it possible to overcome the disadvantages of existing connector designs in terms of high cost, material waste, and non-optimized RF performance due to the use of multi-piece zinc die-cast housings for creating the respective data channel.