Hollow Inner Conductor Contact for Coaxial Connectors
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Solution Overview
Problem
Existing coaxial cable connectors face issues with inter modulation distortion (IMD) and compatibility with hollow aluminum or bi-metal inner conductors due to poor electrical connections and moisture penetration, particularly with softer metals like aluminum that exhibit creep characteristics and galvanic corrosion.
Innovation Solution
A coaxial cable connector inner contact design featuring a spring contact that engages the outer diameter surface of the hollow inner conductor, using a plug with a dielectric material to prevent direct contact with aluminum and a seal to prevent moisture ingress, along with various spring configurations to maintain a secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug type inner contact connection is inserted into the hollow inner conductor, then an electrical connection is created, but the connection becomes mechanically complex and difficult to seal against moisture
Solution Approach 1:
The connection system is divided into two functional segments: a spring contact mechanism for electrical connection and a separate seal component for moisture protection. This segmentation allows each component to perform its specific function optimally without the complexity of integrating both functions into a single plug-type connector.
Solution Approach 2:
A separate seal component acts as an intermediary element between the electrical connection and the environment. This mediator provides moisture protection without interfering with the electrical connection mechanism, simplifying the overall design while maintaining reliability.
2Reliability
If spring contact is applied to hollow aluminum inner conductor, then electrical connection is achieved, but creep characteristics cause connection degradation over time
Solution Approach 1:
The spring contact parameters are specifically designed to account for aluminum's creep characteristics. The spring force, contact pressure, and material selection are optimized to compensate for the softness and creep tendency of aluminum, maintaining stable electrical connection quality over time despite the material's inherent deformation properties.
Solution Approach 2:
The spring contact mechanism is designed with pre-compression and flexible elements that anticipate and compensate for future creep deformation. This beforehand cushioning allows the connection to self-adjust and maintain electrical contact pressure even as the aluminum conductor gradually deforms under sustained load.
3Reliability
If direct metal-to-metal contact is made between inner contact and aluminum inner conductor, then electrical connection is established, but galvanic corrosion and oxidation occur
Solution Approach 1:
A dielectric coating or intermediate layer is introduced between the inner contact and the aluminum inner conductor. This intermediary prevents direct galvanic contact between dissimilar metals, eliminating the electrochemical reactions that cause corrosion and oxidation while still allowing electrical connection through the insulated contact mechanism.
Solution Approach 2:
The connection system uses composite material structures, including dielectric coatings on metal surfaces and multi-layer construction. This composite approach combines the electrical conductivity needed for signal transmission with corrosion-resistant barriers, creating a connection that is both electrically functional and chemically stable.
4Weight of moving object
If hollow aluminum inner conductor is used, then material cost and cable weight are reduced, but compatibility with prior connectors is lost
Solution Approach 1:
Instead of adapting the connector to work with aluminum conductors, the approach is inverted: a specialized spring contact mechanism is developed specifically optimized for aluminum's unique properties. This inversion allows the connector to be perfectly matched to the aluminum conductor's characteristics rather than forcing a compromise design.
Solution Approach 2:
The connector parameters including contact pressure, spring force, material selection, and dimensional specifications are all changed and optimized for aluminum conductors. These parameter changes create a connector that is specifically adapted to hollow aluminum inner conductors, achieving both weight reduction and reliable compatibility.
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 solution enhances IMD performance, reduces material costs, and minimizes deformation and corrosion risks, providing a reliable and cost-effective electrical connection with reduced risk of inter-modulation distortion and environmental failure.
Implementation Method 1
the inner conductor may be movable relative to the outer conductor due to the elasticity of the surrounding foam insulation
Implementation Method 2
the difficulty of forming a reliable electrical connection between dissimilar metals subject to galvanic corrosion and or moisture accelerated oxidation
Data Source
AI summary
A coaxial cable connector inner contact (1) with an interface end (3) and a cable end (5) for a coaxial cable with a hollow inner conductor (11) having an outer diameter surface (9) and an inner diameter surface (29). The inner contact (1) having an inner conductor interface at the interface end (3) and a spring contact (13) proximate the cable end (5) dimensioned to engage the outer diameter surface (9). A plug hole (25) open to the cable end (5) retains a plug (27), the plug (27) dimensioned to insert into the hollow inner conductor (11) and seat against the inner diameter surface (29).