Elastic RF Connector Assembly for Lower-Cost Reliable Mating
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Solution Overview
Problem
Existing 3-piece RF connectors are complex and costly to produce, with high assembly risks and potential quality issues due to multiple parts and assembly challenges, leading to defects that are hard to detect until system-level testing.
Innovation Solution
A simplified RF connector design featuring an outer conductor with a hollow housing and an inner conductor with elastic connection assemblies at both ends, eliminating the need for a separate outer conductor and dielectric insulator, allowing for direct connection and reduced production and assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional 3-piece RF connector design is used (center conductor, insulator, outer conductor), then the connector provides stable electrical connection, but the production complexity and cost increase significantly
Solution Approach 1:
The patent merges the center conductor and insulator into a single integrated component. The center conductor features an integrated insulator structure that is formed as one piece with the conductor, eliminating the need for separate insulator components and reducing assembly steps while maintaining electrical isolation and connection stability
Solution Approach 2:
The patent removes the outer conductor from the connector assembly, using only the integrated center conductor with insulator for the connection. This extraction simplifies the overall structure to essentially a 1-piece design, reducing production complexity while maintaining core electrical connection functionality
2Reliability
If multiple parts are used in the RF connector assembly, then the electrical connection can be optimized, but the assembly process becomes more complex and error-prone
Solution Approach 1:
The center conductor and insulator are merged into a single integrated component with the insulator formed as one piece with the conductor body. This integration eliminates separate assembly steps for attaching the insulator to the center conductor, reducing assembly complexity and potential errors while maintaining electrical isolation quality
Solution Approach 2:
The connector is segmented into only two main components: the integrated center conductor-insulator assembly and the outer housing. This segmentation reduces the total number of parts from three or more to just two, simplifying the assembly process while preserving the necessary electrical connection zones
3Stability of the object's composition
If both center conductor and outer conductor are pressed and mated simultaneously during assembly, then the connector structure is stabilized, but the damage risk increases
Solution Approach 1:
The outer conductor is completely removed from the connector design, eliminating the simultaneous pressing and mating operation between center conductor and outer conductor. The connector is stabilized through the integrated center conductor-insulator structure and outer housing, reducing assembly damage risk while maintaining structural stability
Solution Approach 2:
The insulator is pre-integrated with the center conductor during manufacturing, creating a pre-assembled unit that requires only final insertion into the outer housing. This preliminary integration prevents misalignment and damage during final assembly, as the critical center conductor-insulator interface is already established
4Ease of manufacture
If traditional 3-piece RF connector assembly process is used, then the connector can be manufactured with standard processes, but quality defects are hard to detect until system-level test
Solution Approach 1:
The center conductor and insulator are merged into a single integrated component manufactured as one piece. This integration eliminates interface defects between separate parts, making quality issues more apparent during manufacturing inspection and reducing the occurrence of hidden defects that would only be detected at system-level testing
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 costs, minimizes assembly failures, and improves quality by eliminating co-planarity issues and soldering defects, resulting in a more reliable and cost-effective RF connector.
Implementation Method 1
the male joint or the female joint having elasticity in a radial direction in the area of the abutment connection
Data Source
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.