Modular RF Connector System Misalignment Tolerance
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Solution Overview
Problem
The increasing number of RF electrical signals requires higher connector density per unit area, but existing connectors are limited by human dexterity and misalignment issues, and current solutions like ganged connectors are inflexible and require additional components when port numbers exceed predefined limits.
Innovation Solution
A modular RF connector system that includes a center contact, outer conductor, insulation material, spring washer, and flexible wire, allowing for misalignment tolerance and increased port density through adaptable mounting styles and modular block configurations, enabling efficient connection and self-compensation for impedance changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of electrical connectors is increased to accommodate more RF signals, then the connector density per unit area is improved, but the installation difficulty increases due to limited human dexterity and misalignment issues
Solution Approach 1:
The connector system is divided into modular components including a first connector, a second connector, and an adaptor. Each connector has a standardized interface that can be independently assembled, allowing for easier installation while maintaining high density. The segmentation enables incremental assembly rather than requiring precise alignment of all components simultaneously.
Solution Approach 2:
An adaptor is introduced as an intermediary component between the first and second connectors. The adaptor includes a first interface that mates with the first connector and a second interface that mates with the second connector, facilitating connection while tolerating misalignment. This intermediary element absorbs the alignment tolerance requirements, making installation easier.
2Device complexity
If ganged connectors with predefined ports are used, then the device complexity is reduced, but the adaptability decreases when port numbers exceed predefined limits
Solution Approach 1:
The connector system transitions from static, predefined port configurations to a dynamic, modular assembly. Users can selectively assemble the required number of connectors and adaptors based on the specific application needs, allowing the system to adapt to varying port requirements without being constrained by fixed configurations.
Solution Approach 2:
The standardized interfaces and modular design enable the same basic connector and adaptor components to serve multiple functions and configurations. The same adaptor can be used with different numbers of connectors arranged in various patterns, providing universal applicability across different port requirements.
3Area of stationary object
If connectors are placed closer together to increase density, then the space utilization is improved, but the misalignment tolerance decreases
Solution Approach 1:
The adaptor design incorporates dimensional flexibility through its structural configuration, allowing it to accommodate misalignment in multiple dimensions. The adaptor's geometry provides alignment tolerance in both lateral and axial directions, enabling close spacing of connectors while maintaining reliable electrical connection despite manufacturing variations.
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 system achieves higher connector density per unit area, tolerates misalignment, and allows for various mounting styles, maintaining performance even with axial float, thus addressing the limitations of existing connectors.
Implementation Method 1
The spring is in contact with the first outer conductor and the second outer conductor. The spring is a spring washer. When a force is applied to the first outer conductor, the force is reacted through the spring to the second outer conductor and no through the flexible wire, and, in response to the force, the spring is compressed.
Data Source
AI summary
The electrical connector or device includes a first center contact, a first outer conductor, a first insulation material, a second center contact, a second outer conductor, a second insulation material, a spring, and a flexible wire. The first center contact has a longitudinal axis. The first insulation material is retained between the first center contact and the second outer conductor. The second center contact has a longitudinal axis. The second insulation material is retained between the second center contact and the second outer conductor. The longitudinal axis of the second center contact is substantially perpendicular to the longitudinal axis of the first center contact. The spring is in contact with the first outer conductor and the second outer conductor. The flexible wire is attached to the first center contact and the second center contact.