Modular Filter Connector With Common Shorting Bar
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Solution Overview
Problem
Existing filter connectors are costly due to time-consuming assembly processes and require custom tooling for different configurations, which complicates mass production and affects reliability and performance.
Innovation Solution
A modular filter connector design where terminals and filters are mounted in modules within a larger outer housing, with a common shorting bar and integral biasing means, and interconnecting securing means between modules, allowing for easy customization by changing the outer housing size without altering the modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ground plate is fabricated separately and mounted to the dielectric housing, then the connector can be assembled, but the assembly process becomes time-consuming and costly
Solution Approach 1:
The ground plate is integrated directly into the dielectric housing as a unified component rather than being a separate part. This merging eliminates the need for separate mounting operations, reducing assembly time and steps while maintaining the grounding function and improving assembly reliability.
Solution Approach 2:
The dielectric housing serves multiple functions: it provides structural support, electrical insulation, and integrated grounding through the incorporated ground plate. This multi-functionality reduces the total number of components and assembly operations required.
2Adaptability or versatility
If custom tooling is used for different connector configurations, then specific connector requirements are met, but manufacturing complexity and cost increase
Solution Approach 1:
The connector is divided into modular components (terminal modules, filter modules, dielectric housing with integrated ground plate) that can be independently manufactured using standard tooling. These modules are then assembled in different configurations to meet specific connector requirements, eliminating the need for custom tooling for each configuration.
Solution Approach 2:
Connector configurations are adjusted by changing assembly parameters (number and arrangement of modules) rather than changing the fundamental tooling or component designs. This allows versatile connector configurations to be achieved with standardized manufacturing processes.
3Reliability
If multiple separate assembly steps are used for terminals, filters, and ground plate, then each component can be optimized, but the overall manufacturing cost increases
Solution Approach 1:
The ground plate and dielectric housing are merged into a single integrated component, reducing the total number of parts and assembly steps. This integration maintains the optimization of individual components while significantly reducing manufacturing complexity and cost through fewer assembly operations.
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 simplifies and reduces the cost of manufacturing by allowing customization of the connector without changing the modules, enabling efficient assembly and improved reliability and performance in mass production.
Implementation Method 1
biasing means are provided between the shorting bar and the filters to bias the filters against the terminals
Data Source
AI summary
A modular filter connector (10) includes an outer housing (12) having a cavity. A plurality of inner housing modules (16) are positionable in the cavity in a side-by-side array. At least one terminal (28) is mounted in each housing module to define at least one row of terminals along the cavity. A filter (34) is mounted in each housing module electrically coupled to each terminal to define at least one row of filters. A common shorting bar (36) spans the plurality of housing modules and is electrically coupled to the plurality of filters of the modules.