Micro RF Connector Plug With Integrated Locking for Stable Assembly
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Solution Overview
Problem
Existing micro RF connector plugs face issues such as detachment after plugging, high material and processing costs, and difficulty in automated production due to smooth conductor surfaces and complex assembly processes.
Innovation Solution
The design includes an inner conductor, outer conductor with radial pins, and an insulator with coaxial rings and locking structures for secure connection, along with a continuous stamping process for precise manufacturing, eliminating the need for assembly and enhancing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer conductor is processed with a stretch film and a fixing structure is added, then the connection stability is improved, but the total processing cost increases
Solution Approach 1:
The patent integrates the locking structure directly into the insulator body, merging the functions of insulation and mechanical locking into a single component. This eliminates the need for separate fixing structures and stretch films, thereby maintaining connection stability while reducing processing costs and simplifying manufacturing.
Solution Approach 2:
The insulator's locking structure is designed to automatically engage with the receptacle during insertion, providing self-locking functionality without requiring additional fixing mechanisms or complex assembly processes. This self-service approach improves reliability while keeping manufacturing simple.
2Strength
If the outer conductor is made of zinc alloy, then the material cost increases, but the structural strength is improved
Solution Approach 1:
The patent applies different material properties to different parts of the connector. The outer conductor uses a cost-effective material (such as copper or copper alloy) while the insulator incorporates the locking function. This local differentiation allows optimization of each component's material selection based on its specific functional requirements, reducing overall material cost while maintaining necessary strength.
Solution Approach 2:
The patent employs composite construction where the insulator material (such as plastic or polymer) combines electrical insulation properties with mechanical locking capabilities. This composite approach allows the use of cheaper materials for the conductor while the insulator provides the structural support and locking function, overall reducing material costs.
3Ease of manufacture
If smooth cavity bodies are provided on both inner and outer walls of the conductors, then the manufacturing process is simplified, but the connection stability deteriorates
Solution Approach 1:
The patent divides the connector into distinct functional segments: the conductor portion with smooth surfaces for electrical contact, and the insulator portion with locking structures for mechanical stability. This segmentation allows each part to be optimized for its specific function - electrical conduction or mechanical locking - resolving the contradiction between manufacturing simplicity and connection stability.
Solution Approach 2:
The insulator acts as an intermediary component that bridges the conductor and receptacle, providing the locking function that the smooth-conducted conductors lack. This intermediary structure enables connection stability without requiring complex surface treatments on the conductors themselves, maintaining manufacturing simplicity while improving reliability.
4Reliability
If complex assembly processes are used to ensure proper connection, then the connection reliability is improved, but the difficulty of automated production increases
Solution Approach 1:
The locking structure is designed to automatically engage and lock the plug and receptacle together during the insertion process itself. This self-locking mechanism eliminates the need for complex post-assembly operations or specialized assembly equipment, making the process inherently suitable for automated production while ensuring reliable connections.
Solution Approach 2:
The locking structures are pre-configured on the insulator and receptacle components during manufacturing. When the plug is inserted into the receptacle, these pre-configured structures automatically align and engage, providing reliable locking without requiring complex real-time assembly operations. This preliminary preparation enables simple, automated assembly processes.
Data Source
AI summary
Micro RF connector plugs, assemblies thereof, and methods of processing such plugs are described. The RF plugs include an outer conductor (2) having an outer conductor ring (201) with a plurality of pins (202) extending therefrom and an axis therethrough. An inner conductor (1) arranged within the outer conductor includes a central needle (101) along the axis and an extending needle (102) in a direction normal to the axis and extending through a gap between two adjacent pins of the outer conductor. An insulator (3) isolates the inner conductor from the outer conductor and includes an outer ring (301), an inner ring (302), and a base (303) connecting the outer and inner ring. The outer conductor ring is embedded between the outer and the inner ring. First and second locking structures (203, 304) are configured to securely connect and lock the connector plug into connection with a connector receptacle.