Elastic RF Connector Assembly for Lower-Cost Reliable Mating
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Solution Overview
Problem
Existing RF connectors have a complex 3-piece design that leads to high production and assembly costs, potential quality issues, and increased risk of damage during assembly, with quality defects often not detected until system-level testing.
Innovation Solution
A simplified RF connector design featuring an elastic connection assembly with a central body and outer conductor, eliminating the need for a dielectric insulator and allowing for easier assembly and reduced production costs, while improving quality and lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional 3-piece design (center conductor, insulator, outer conductor) is used, then the RF connector provides reliable electrical connection, but the production cost and assembly complexity increase significantly
Solution Approach 1:
The patent combines the center conductor and insulator into a single integrated elastic connection assembly. The elastic connection body integrates both the conductive center conductor portion and the insulating portion that supports it, eliminating the need for separate insulator and center conductor components. This merging reduces the number of parts from 3 to 2 while maintaining the electrical connection reliability through the integrated structure.
2Ease of operation
If a traditional 3-piece design is used, then the RF connector can be assembled, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
By integrating the center conductor and insulator into the elastic connection assembly, the patent reduces the number of assembly steps. Instead of assembling three separate components (center conductor, insulator, outer conductor), the assembly process now involves fitting two integrated components (elastic connection assembly, outer conductor), thereby simplifying the assembly process and reducing assembly time.
Solution Approach 2:
The elastic connection assembly incorporates elastic elements that provide automatic adjustment during assembly. The elastic biasing mechanism allows the connection assembly to self-adjust to the mating connector, reducing the need for precise manual alignment and speeding up the assembly process while ensuring reliable electrical contact.
3Ease of operation
If both center conductor and outer conductor are pressed simultaneously during assembly, then the connector can be assembled, but the damage risk increases
Solution Approach 1:
The patent segments the assembly process into two distinct stages: first inserting the elastic connection assembly (center conductor) into the mating connector, then separately installing the outer conductor. This segmentation allows each component to be positioned and secured independently, eliminating the risk of simultaneous pressing damage that occurs when trying to install both conductors at the same time.
Solution Approach 2:
The elastic connection assembly is pre-assembled with the center conductor and insulator integrated before insertion into the mating connector. This preliminary integration ensures the center conductor is properly positioned and supported before the outer conductor is installed, preventing misalignment and damage during the assembly process.
4Ease of manufacture
If a simplified 2-piece design is used, then production cost decreases, but the manufacturing precision requirements may increase
Solution Approach 1:
The integration of the center conductor and insulator into the elastic connection assembly requires precise manufacturing of the integrated structure. The patent achieves this by designing the elastic connection body to inherently position the center conductor correctly through its elastic biasing mechanism, reducing the need for additional precision adjustments and simplifying the manufacturing process despite the integrated design.
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 simplified design reduces production and assembly costs, minimizes assembly failures, and enhances the durability of the RF connector, addressing the issues of the traditional 3-piece design.
Implementation Method 1
an elastic connection assembly with a central body and outer conductor
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~2A
AI summary
A radio frequency connector is disclosed, comprising: an outer conductor having a hollow housing with outer electrical contacts at its ends; and an inner conductor comprising a central body configured to be installed inside the outer conductor and spaced from the outer conductor with an annular space therebetween. In each end region of the central body of the inner conductor, an elastic connection assembly is provided for electrically connecting the central body to a component to be connected. The elastic connection assembly comprises a male joint and a female joint which mate with each other to form an abutment connection, the male joint or the female joint having elasticity in a radial direction in the area of the abutment connection, one of the male joint and the female joint being provided on the central body, and the other of the male joint and the female joint being provided on the component to be connected. The central body of the inner conductor is directly connected to the component to be connected by means of the elastic connection assembly, without involving the outer conductor. A communication module comprising the above-said radio frequency connector is also disclosed.