Moveable Insulator Connector Assembly for RF Gap Continuity
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Solution Overview
Problem
Existing electrical connector assemblies experience capacitive discontinuities due to air gaps between insulative housings, leading to degraded radio frequency (RF) and electromagnetic performance.
Innovation Solution
Incorporation of a helical coil spring that exerts a longitudinal force on the insulative housing within the shield terminal, maintaining mechanical contact and reducing air gaps, combined with a conductive sleeve to cover coil spring gaps, enhancing compressive and redundant contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed insulative housing is used in existing electrical connector assemblies, then the structure is simple and easy to manufacture, but air gaps form between insulative housings causing capacitive discontinuities that degrade RF and electromagnetic performance
Solution Approach 1:
The insulative housing is transformed from a fixed structure to a moveable one, allowing it to dynamically adjust its position along the longitudinal axis in response to spring force and mating conditions. This dynamic capability enables the housing to eliminate air gaps and maintain continuous RF pathways, resolving the contradiction between structural simplicity and RF performance.
Solution Approach 2:
The longitudinal position parameter of the insulative housing is made variable through the spring mechanism. By changing the position parameter dynamically rather than keeping it fixed, the system achieves continuous RF performance while accepting increased structural complexity.
2Reliability
If a moveable insulative housing with spring mechanism is implemented, then capacitive discontinuities are minimized and RF performance is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The connector assembly is segmented into distinct functional modules: the moveable insulative housing, the spring mechanism, the shield terminal, and the mating connector components. This segmentation allows each module to be manufactured and assembled independently, reducing overall manufacturing difficulty despite the increased complexity of individual components.
Solution Approach 2:
The spring mechanism acts as an intermediary element between the insulative housing and the shield terminal, providing the necessary force to maintain contact while simplifying the connection interface. This intermediary component enables the moveable housing design to be manufactured more easily by decoupling the complexity of motion maintenance from the housing structure itself.
3Reliability
If the insulative housing is made moveable within the shield terminal, then mechanical contact and RF continuity are maintained through longitudinal adjustment, but the manufacturing precision requirements increase
Solution Approach 1:
The spring mechanism provides beforehand cushioning by pre-loading the insulative housing in a compressed state, creating a force reserve that automatically compensates for manufacturing tolerances and assembly variations. This prior cushioning eliminates the need for extremely tight manufacturing precision in longitudinal positioning while maintaining reliable mechanical contact and RF continuity.
Solution Approach 2:
The system changes from a fixed position parameter to a variable position parameter controlled by spring force. This parameter change allows the housing to self-adjust to the optimal position within tolerance ranges, reducing the stringency of manufacturing precision requirements while maintaining contact reliability.
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
Improves RF and electromagnetic performance by minimizing capacitive discontinuities and providing robust electrical connections through enhanced mechanical and electrical contact.
Implementation Method 1
a helical coil spring that exerts a longitudinal force on the insulative housing within the shield terminal, maintaining mechanical contact and reducing air gaps
Implementation Method 2
combined with a conductive sleeve to cover coil spring gaps, enhancing compressive and redundant contact points
Data Source
AI summary
An electrical connector assembly includes a central electrical terminal connected to a cable terminal attached to an end of a central conductor of an electrical cable configured to mate with a corresponding mating central electrical terminal. The central electrical terminal comprises a helical coil spring in compressive contact with the cable terminal. The assembly also includes an insulative housing defining a cavity in which the central electrical terminal is affixed and a shield terminal in which the insulative housing, central electrical terminal, and coil spring are disposed. The insulative housing is configured to move longitudinally within the shield terminal. The coil spring exerts a longitudinal force on the central electrical terminal and the insulative housing to maintain mechanical contact between the insulative housing and a corresponding insulative housing in which the corresponding mating central electrical terminal is disposed.