Monolithic Insulator Ramp Surface Progressive Bias
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Solution Overview
Problem
Existing coaxial cable connectors face issues with high insertion forces and potential impedance discontinuities due to increased spring finger dimensions or configurations, and prior solutions either require high axial compression that can deform the insulator or introduce additional manufacturing and assembly complexities.
Innovation Solution
A monolithic insulator with deflectable spring fingers and ramp surfaces that provide a progressive inward bias to the spring basket, reducing insertion force and preventing permanent deformation, while maintaining efficient electrical interconnection and assembly simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring finger dimensions are increased to improve mechanical and electrical interconnection, then the interconnection quality is improved, but insertion force increases unacceptably
Solution Approach 1:
The insulator incorporates a progressive collapse mechanism that transitions from a rigid structure to a deformed state during assembly. The collapse feature allows the insulator to dynamically adjust its shape, enabling the spring fingers to be biased inward progressively rather than requiring full force at once. This dynamic behavior resolves the contradiction by distributing the insertion force over the assembly process while maintaining strong final interconnection.
Solution Approach 2:
The insulator's radial dimension changes progressively during assembly through the collapse feature. The collapse characteristic modifies the insulator's physical parameters (radial position, shape) as compression is applied, allowing the spring fingers to transition from a relaxed state to a biased state. This parameter change enables improved interconnection without requiring unacceptably high insertion force.
2Reliability
If steady state spring finger configuration is modified to increase radial inward bias, then interconnection is improved, but insertion force increases unacceptably
Solution Approach 1:
The collapse feature is pre-configured in the insulator to enable progressive radial inward movement during assembly. This preliminary structural design allows the spring fingers to be biased inward as the insulator collapses, rather than requiring the spring fingers to maintain a pre-biased configuration that would demand high insertion force. The preliminary action is built into the insulator's geometry to achieve improved interconnection with acceptable force.
3Reliability
If axial compression is applied to collapse insulator radially inward, then spring basket bias is improved, but insulator permanent deformation occurs preventing re-use
Solution Approach 1:
The insulator is designed with elastic collapse characteristics that allow reversible deformation. When axial compression is applied during assembly, the collapse feature enables the insulator to deform radially inward to bias the spring basket. However, the elastic properties of the insulator material and structure allow it to recover its original shape after assembly, maintaining re-usability. The dynamic elastic behavior resolves the contradiction between achieving spring basket bias and preserving connector re-usability.
4Reliability
If multiple insulator elements are used to progressively bias spring basket, then spring finger bias is improved, but manufacturing and assembly complexity increases
Solution Approach 1:
The patent combines multiple functions into a single monolithic insulator structure. The collapse feature integrates the progressive biasing mechanism, spring finger support, and insulator functions into one component. This merging eliminates the need for multiple separate insulator elements that would interact through wedge surfaces, thereby reducing manufacturing and assembly complexity while maintaining the progressive spring finger bias capability.
Solution Approach 2:
The single insulator structure performs multiple functions: it supports the inner contact, provides electrical insulation, and progressively biases the spring basket through its collapse feature. This multi-functional design eliminates the need for separate components for each function, reducing device complexity while achieving the desired spring finger bias through the integrated collapse mechanism.
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 the mechanical and electrical performance of coaxial connectors by reducing insertion force, preventing insulator deformation, and simplifying assembly, thereby improving reliability and cost-effectiveness.
Implementation Method 1
A monolithic insulator with deflectable spring fingers and ramp surfaces that provide a progressive inward bias to the spring basket
Data Source
AI summary
An insulator supporting an inner contact coaxial within a connector body bore of a connector for coaxial cable with a solid outer conductor is formed as a monolithic body with an inner contact bore extending between a connector end and a cable end. The inner contact bore is dimensioned to receive the inner contact. An outer diameter of the insulator at the connector end is configured to mate with the connector body bore of the coaxial cable connector. A plurality of spring fingers extends from the cable end of the insulator. A distal end of the spring fingers each is provided with a ramp surface, whereby during connector to cable assembly, the solid outer conductor contacts the spring fingers along the ramp surface(s), deflecting the spring fingers inward to increase inward bias upon a spring basket of the inner contact.