Intermodulation-Free HF Contact With Spherical Punctiform Geometry
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Solution Overview
Problem
High-frequency electrical contacts often suffer from undefined contacts due to unfavorable shapes and tolerances, leading to undesirable intermodulation products and increased production costs, as high forces are required to achieve a permanent and strong connection.
Innovation Solution
The arrangement involves a conductive element with a contact area having a radius at predetermined points, allowing for punctiform contacting and tolerance compensation, enabling reproducible, intermodulation-free connections with reduced force requirements and economical production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high force is applied during pressing to achieve permanent and strong contact, then contact strength is improved, but production costs and energy consumption increase
Solution Approach 1:
The contact points are designed with a spherical geometry having a specific radius. This curvature allows the contact to accommodate surface irregularities and angular misalignments without requiring excessive pressing force, thereby reducing production costs while maintaining adequate contact strength.
Solution Approach 2:
The invention changes the geometric parameter of the contact surface from flat to spherical with a specific radius. This parameter change enables the contact to be less sensitive to tolerances in flatness and angular alignment, reducing the force required during assembly and lowering production costs.
2Reliability
If high force is applied during pressing to compensate for tolerances, then contact reliability is improved, but energy consumption increases
Solution Approach 1:
The spherical contact points with a defined radius inherently compensate for surface tolerances and angular misalignments. This geometric design ensures reliable electrical contact without requiring high pressing forces, thereby reducing energy consumption during the assembly process while maintaining contact reliability.
3Ease of manufacture
If flat surfaces are used for contact, then manufacturing is simplified, but undefined contacts and intermodulation occur due to tolerances
Solution Approach 1:
Instead of using flat surfaces that are sensitive to tolerances in flatness and angular alignment, the invention employs spherical contact points with a specific radius. This curvature ensures that contact occurs at well-defined points, eliminating undefined contacts and preventing intermodulation, while still being manufacturable through standard processes.
Solution Approach 2:
The invention applies a localized spherical geometry specifically at the contact points rather than making the entire surface complex. This local quality change ensures well-defined contact areas while keeping the rest of the structure simple and easy to manufacture.
4Manufacturing precision
If complex geometry is used to reduce tolerances, then contact precision is improved, but construction costs increase
Solution Approach 1:
The spherical contact points with a defined radius provide a simple yet effective geometric solution that inherently compensates for tolerances in flatness and angular alignment. This relatively simple geometric form achieves high contact precision without requiring complex construction, thereby avoiding increased construction costs.
Data Source
Figure 1a~2
Figure 3~4c
Figure 5~7
AI summary
An arrangement for electrically contacting electrically conductive elements is provided, comprising a first element electrically conductive at least in one section, and at least a second element electrically conductive at least in one section for electrically contacting the first element, comprising a contact area at at least one end region thereof, wherein the contact area has a radius at least at predetermined contact points. The first electrically conductive element has at least one region configured to receive at least a portion of the contact area of the second electrically conductive element such that an electrical contact is established between the first electrically conductive element and the contact points of the second electrically conductive element. Furthermore, corresponding first and second elements are provided.