Floating Angle Plug Contact for Safe Coaxial Assembly
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Solution Overview
Problem
Existing right-angle connectors for coaxial cables in the automotive industry face challenges in cost-effective mass production, easy and safe mounting, and ensuring functional reliability under stress, with potential for undetectable damage during assembly leading to later failures.
Innovation Solution
The angle plug design features a floating first contact piece that can shift and adapt to the pin-shaped second contact piece, secured by a spring-elastic tongue for easy assembly and secure anchoring, with a guidance system preventing sideways movement and using a small hole for optical verification of correct insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the first contact piece is fixed rigidly in the dielectric part, then the structural stability is improved, but the assembly safety deteriorates because the contact piece cannot adapt to position variations during insertion
Solution Approach 1:
The first contact piece is designed to be movable within the dielectric part rather than rigidly fixed. It can shift position and rotate to adapt to variations in the insertion position of the pin-shaped second contact piece, while still maintaining stable electrical connection. This dynamic design resolves the contradiction by allowing the contact piece to be both stable in its electrical function and adaptable in its physical position during assembly.
Solution Approach 2:
The contact piece is divided into a first contact piece (in the dielectric part) and a second contact piece (the pin-shaped connector), with the first contact piece further segmented into contact surfaces that can move independently. This segmentation allows different parts to have different degrees of freedom - the overall structure remains stable while the contact surfaces can adapt to position variations.
2Reliability
If the first contact piece is made displaceable to improve assembly safety, then the manufacturing complexity increases
Solution Approach 1:
The first contact piece is designed with simple movable elements that can shift and rotate within the dielectric part. The movement is achieved through basic mechanical clearance and elastic deformation rather than complex mechanisms, keeping the manufacturing process relatively simple while providing the necessary adaptability for safe assembly.
Solution Approach 2:
The design allows for simple parameter adjustments in the manufacturing process, such as controlling the clearance dimensions and material elasticity, to achieve the desired movability of the first contact piece without requiring complex manufacturing steps or additional components.
3Difficulty of detecting and measuring
If a large window is provided in the housing for optical verification, then the quality control capability is improved, but the high-frequency radiation losses increase
Solution Approach 1:
The optical verification function is extracted from a large window requirement to a small hole sufficiency. The design allows optical detection of correct pin insertion through a minimal opening in the housing, eliminating the need for large windows that would cause high-frequency radiation losses while maintaining quality control capability.
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 design enhances the safety and reliability of assembly, allows for cost-effective manufacturing, and simplifies quality control through optical verification, preventing damage and ensuring a reliable electrical connection.
Implementation Method 1
the first contact piece has a spring-elastic tongue, which is arranged in the said opening and essentially inseparably connects the inserted pin-shaped part to the first contact piece
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The angular connector (1) has a housing (2), in which a contact piece (10) is pivotably arranged in a dielectric part (8). Another contact piece (20) is connected with a cable, and has a pin-shaped part (21) provided together for electrical and mechanical connection of the former and latter contact pieces. The pin-shaped part is inserted in an opening (6) of the former contact piece, and is fixed in the opening. The former contact piece is float mounted in dielectric part in a direction.