Flexible Outer Contacts for High Signal Isolation Connectors
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Solution Overview
Problem
High density RF connectors face significant signal leakage issues at the interface with printed circuit boards, particularly with all-metal construction and press-fit connections, where existing solutions like increased ground contacts or compressible gaskets are inadequate for tight isolation specifications and are prone to misalignment and long-term reliability concerns.
Innovation Solution
The use of mechanically flexible outer contacts with flared tines and lip portions surrounding central signal contacts, which adapt to varying hole diameters and tolerances in the shim, ensuring consistent 360-degree contact and enhanced signal isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If press-fit connection is used for large mass connectors, then ease of manufacture is improved, but signal isolation deteriorates
Solution Approach 1:
The connector is divided into modular components: a connector body, a separate metal component (shim) with precisely positioned holes, and press-fit contacts. This segmentation allows each component to be optimized independently - the metal component can be precisely manufactured with hole patterns, while the connector body can be designed for press-fit assembly, achieving both ease of manufacture and signal isolation.
Solution Approach 2:
A metal component (shim) with precisely positioned holes is introduced as an intermediary element between the connector body and PCB. This intermediary provides precise mechanical alignment and electrical isolation, enabling press-fit connections to achieve signal isolation levels previously only attainable with soldered connections.
2Ease of manufacture
If metal component with array of holes is used, then ease of manufacture is improved, but signal isolation deteriorates due to leakage through holes
Solution Approach 1:
The metal component with holes is segmented and paired with press-fit contacts that insert into each hole. This segmentation transforms the potential leakage path (holes) into a controlled interface where the press-fit contact makes precise 360-degree contact with the hole interior, blocking signal leakage while maintaining the manufacturing simplicity of the holed metal component.
Solution Approach 2:
The holes in the metal component, which initially appear to be leakage paths, are converted into beneficial alignment features. The press-fit contacts use these holes as precise mechanical guides to achieve perfect positioning and 360-degree electrical contact, turning the potential harm (leakage through holes) into a benefit (precise alignment and isolation).
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 flexible outer contacts effectively prevent signal leakage and crosstalk by compensating for manufacturing inconsistencies and misalignment, maintaining high signal isolation over time despite environmental factors like temperature and vibration.
Implementation Method 1
Each of the tines has a flexible arm with a lip portion at a distal end thereof. The lip portion has an outer lead-in surface that tapers outwardly from the second end of the conductive body toward the first end. The lip portion has an outer shielding contact surface. Each of the outer shielding contact surfaces is adapted to contact the inner diameter surface of the at least one hole of the metal component.
Data Source
AI summary
An electrical connector for mounting to a printed circuit board that has a connector housing with a printed circuit board interface and a port supporting a central signal contact, and a metal component at the printed circuit board interface that has a hole corresponding the port. An outer contact is disposed in the port and surrounding the signal contact. The outer contact includes a conductive body that has a first end forming a ring and outwardly flared tines extending from the ring. Each tine has a flexible arm with a lip portion at a distal end thereof. The lip portion has an outer lead-in surface that tapers outwardly from the second end of the conductive body toward the first end. The lip portion has an outer shielding contact surface each adapted to contact the inner diameter surface of the hole of the metal component.