Insulating Knuckle Coupling Electrically Isolated Conductive Sections
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Solution Overview
Problem
In electronic devices, components used in multiple electrical circuits require electrical isolation to function correctly, which is challenging when constructed from conductive sections, as they need to be separated by insulating materials to prevent cross-talk and ensure proper circuit operation.
Innovation Solution
The use of knuckles made from insulating materials, overmolded around brackets welded to conductive sections, physically couples and electrically isolates these sections by maintaining a predetermined distance between them, minimizing capacitance and enhancing antenna performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive sections are separated by insulating materials to ensure electrical isolation, then electrical circuit functionality is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The insulating material is nested within the recesses of the conductive sections, with the insulating material fitting inside the recesses formed in each conductive section. This nesting approach allows electrical isolation to be integrated within the existing structural geometry rather than adding external isolation components.
Solution Approach 2:
The patent combines the structural support function and electrical isolation function into a single integrated solution. The insulating material serves dual purposes: filling the recesses to provide mechanical support and maintaining spacing, while simultaneously providing electrical isolation between adjacent conductive sections.
2Reliability
If insulating materials are used to separate conductive sections, then electrical isolation is improved, but manufacturing precision requirements increase
Solution Approach 1:
Recesses are pre-formed in the conductive sections during the manufacturing process before final assembly. These recesses are created at predetermined locations and dimensions to accommodate the insulating material, ensuring that the spacing and isolation requirements are built into the structure rather than requiring precise post-assembly adjustments.
Solution Approach 2:
The patent specifies predetermined dimensions for the recesses and the insulating material to optimize the spacing between conductive sections. By carefully controlling the parameters of the recess geometry and insulating material size, the design achieves the required electrical isolation while accommodating normal manufacturing tolerances.
3Reliability
If conductive sections are spaced apart to minimize capacitance, then antenna performance is improved, but mechanical strength may be reduced
Solution Approach 1:
The insulating material is nested within recesses that are integral to the conductive sections, creating a interlocking structure. The recesses are formed to accommodate the insulating material, which then provides both electrical isolation and mechanical support, helping to maintain the structural integrity of the assembled device.
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 method effectively couples and isolates conductive sections, ensuring proper electrical functionality and improving mechanical integrity while reducing capacitance, thus enhancing the performance of electronic devices, particularly in applications like antennas.
Implementation Method 1
maintaining a predetermined distance between them, minimizing capacitance
Implementation Method 2
overmolded around brackets welded to conductive sections
Data Source
AI summary
Each knuckle is molded in and/or around a coupling structure that is either welded to or is an integral part of the section. The coupling structure can be a bracket that is welded to an inner surface of a section, and the bracket is constructed to have a cross-section that minimizes capacitance. In one embodiment, a first bracket can be welded to a first conductive section, and a second bracket can be welded to a second conductive section. A knuckle constructed from an insulating material that is overmolded within and around the first and second brackets such that the first and second conductive sections are coupled together. The first and second conductive sections and their respective brackets are spaced a predetermined distanced apart, thereby ensuring the conductive sections are electrically isolated.