Elastic Coaxial Contactor Structure for Low-Resistance Connection
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Solution Overview
Problem
Conventional coaxial cables and connectors face manufacturing complexity and lack elastically deformable components for secure connection and signal transfer, leading to increased contact resistance and assembly challenges.
Innovation Solution
A contactor with a core, insulation, and shield part, all elastically deformable and integrally formed, allowing for reliable connection and signal transfer, with the core and shield parts containing conductive particles to enhance conductivity and the insulation part ensuring separation and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional coaxial cable and connector components are manufactured and assembled individually, then manufacturing flexibility is maintained, but manufacturing complexity increases and assembly becomes difficult
Solution Approach 1:
The patent merges the coaxial cable and connector into a single integrated contactor structure where the core part, insulation part, and shield part are formed as one piece. This eliminates the need for separate assembly of multiple components, thereby reducing manufacturing complexity and assembly difficulty while maintaining manufacturing flexibility.
Solution Approach 2:
The integrated contactor structure performs multiple functions simultaneously: the core part provides signal transmission, the insulation part provides electrical isolation, and the shield part provides electromagnetic shielding. This multi-functional design eliminates the need for separate components, simplifying both manufacturing and assembly processes.
2Reliability
If rigid components are used in the contactor, then structural stability is improved, but connection reliability decreases due to inability to accommodate surface tolerances and shape differences
Solution Approach 1:
The patent changes the physical state of the contactor components from rigid to elastically deformable. This parameter change allows the core part, insulation part, and shield part to deform elastically during insertion and connection, enabling them to accommodate surface tolerances and shape differences between mating components, thereby improving connection reliability while maintaining structural stability through elastic recovery.
3Reliability
If elastically deformable components are used, then connection reliability is improved through close contact, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs the flexible shell concept by making the core part, insulation part, and shield part elastically deformable. This flexibility compensates for minor dimensional variations and surface irregularities that occur during manufacturing, reducing the stringency of manufacturing precision requirements while ensuring reliable close contact between mating components.
Solution Approach 2:
The elastic deformability of the contactor components provides beforehand cushioning against dimensional tolerances and shape differences. The elastic deformation capability acts as a buffer that absorbs manufacturing variations, ensuring reliable connection without requiring extremely tight manufacturing precision.
4Productivity
If multiple separate components are used, then functional specialization is improved, but assembly time and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components (coaxial cable and connector) into a single integrated contactor structure. This merging reduces the number of components from multiple separate parts to one unified structure, thereby eliminating assembly steps and significantly improving assembly efficiency and productivity while reducing manufacturing cost.
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
The solution enables reliable connection and reduced contact resistance through elastic deformation, accommodating surface tolerances and shape differences, while simplifying assembly and reducing manufacturing costs by integrating components.
Implementation Method 1
a core part configured to extend in a longitudinal direction, contain a conductive particle and be formed to be elastically deformable; an insulation part configured to surround a transverse surface of the core part and be formed to be elastically deformable; and a shield part configured to surround a transverse surface of the insulation part to be spaced apart from the core part, contain a conductive particle and be formed to be elastically deformable
Data Source
AI summary
A contactor for connection and signal transfer between conductors includes: a core part configured to extend in a longitudinal direction, contain a conductive particle and be formed to be elastically deformable; an insulation part configured to surround a transverse surface of the core part and be formed to be elastically deformable; and a shield part configured to surround a transverse surface of the insulation part to be spaced apart from the core part, contain a conductive particle and be formed to be elastically deformable.