Dual-Contact Outer Conductor for Automotive Connectors
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Solution Overview
Problem
Existing electrical connectors in the automotive industry face challenges in providing a high shielding effect and low contact resistance for high-frequency signal transmission while maintaining robustness and ease of assembly, particularly in the transition area between the outer conductor assembly and the electrical assembly, and require economic mass production and reduced assembly forces.
Innovation Solution
The use of a dual-contact-element outer conductor assembly with press-fit pins and spring-loaded contact elements, where press-fit pins provide a gas-tight connection and spring-loaded elements reduce mechanical stress, allowing for increased contact density and reduced contact resistance, enabling efficient electromagnetic shielding and impedance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press-fit pins are pressed into metalized recesses under high press-in pressure to achieve gas-tight connection and low contact resistance, then contact resistance is reduced and shielding effect is improved, but mechanical stress on the electrical assembly increases and risk of cracks and fractures increases
Solution Approach 1:
The contact elements are divided into two distinct groups: press-fit pins for gas-tight connection and spring-loaded contact elements for reduced mechanical stress. This segmentation allows each type to perform its specific function optimally without compromising the other.
Solution Approach 2:
The invention changes the mechanical parameters of the contact elements by introducing spring-loaded elements with elastic properties. These elements can deform elastically under press-in force and maintain contact pressure without requiring high static press-in pressure, thereby reducing mechanical stress on the electrical assembly.
2Manufacturing precision
If the distance between adjacent press-in pins is reduced to increase contact density and improve shielding effect, then shielding effect is enhanced and contact resistance is reduced, but the risk of cracks and fractures in the electrical assembly increases
Solution Approach 1:
The contact elements are segmented into press-fit pins and spring-loaded contact elements. This segmentation enables closer spacing of contact elements to improve shielding effect, while the spring-loaded elements absorb mechanical stress through elastic deformation, preventing cracks and fractures in the electrical assembly.
Solution Approach 2:
The spring-loaded contact elements introduce dynamic behavior to the connection system. They can deform elastically during assembly and maintain contact pressure through their spring force, allowing for closer spacing of contact elements without compromising the structural integrity of the electrical assembly.
3Reliability
If maximum press-in pressure is applied to achieve cold welding and integral connection between press-in pins and recesses, then connection reliability is improved, but the maximum press-in pressure is limited to avoid formation of cracks and fractures
Solution Approach 1:
The contact elements are divided into press-fit pins that achieve gas-tight connection through cold welding and spring-loaded contact elements that maintain connection through elastic deformation. This segmentation allows for reliable connection without requiring excessive press-in pressure that would cause cracks and fractures.
Solution Approach 2:
The spring-loaded contact elements act as a cushioning mechanism during assembly. They absorb excess press-in force through elastic deformation and prevent the transmission of high mechanical stress to the electrical assembly, thereby avoiding cracks and fractures while maintaining connection reliability.
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 configuration enhances the shielding effect and reduces contact resistance, ensuring reliable high-frequency signal transmission while minimizing mechanical stress on components and simplifying assembly, making it suitable for high-frequency applications in the automotive sector.
Implementation Method 1
a second group of contact elements is designed as spring-loaded contact elements for insertion into the metallized recesses of the electrical assembly
Implementation Method 2
For this purpose, several press-in pins of the outer conductor assembly are pressed into associated metalized recesses of the electrical assembly under a certain press-in pressure. In this way, cold welding is caused and an integral connection occurs between the press-in pins and the recesses.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to an external conductor assembly (6) for an electrical connector (2). The external conductor assembly (6) has a first interface (9) for electrical and mechanical contacting of an external conductor of a corresponding electrical mating connector and a second interface (10) for electrical and mechanical contacting of metallized recesses (11) of an electrical assembly (3). The second interface (10) has a plurality of contact elements (12, 13) for contacting the electrical assembly (3). It is provided that a first group of contact elements is designed as press-fit pins (12) for interference fitting in the metallized recesses (11) of the electrical assembly (3), and a second group of contact elements is designed as spring-loaded contact elements (13) for insertion into the metallized recesses (11) of the electrical assembly (3).