Plug Connector Radial Spring Contact for High-Frequency Reliability
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Solution Overview
Problem
High-frequency connectors, such as 7-16 (DIN) connectors, face challenges in maintaining consistent mechanical and electrical properties due to compact design and temperature fluctuations, leading to intermodulation issues and the need for high tightening torque to achieve adequate contact pressure.
Innovation Solution
The solution separates the mechanical limit stop from the electrical contact function, allowing for radial spring contacts to establish consistent outer conductor contacting without axial end-to-end contact, reducing the reliance on high torque and minimizing the impact of material relaxation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high contact pressure is used to ensure good intermodulation properties, then electrical contact quality is improved, but material relaxation occurs leading to changes in mechanical and electrical properties over time
Solution Approach 1:
The patent employs spring elements that provide dynamic contact pressure maintenance. The spring mechanism automatically compensates for material relaxation by exerting continuous elastic force, ensuring consistent electrical contact pressure without relying on rigid mechanical preloading that would cause stress concentration and material fatigue over time.
Solution Approach 2:
The invention changes the contact mechanism from rigid mechanical pressing to elastic spring-based contact. This parameter change allows the system to maintain optimal contact pressure through the spring's elastic properties, accommodating material relaxation while preserving electrical contact quality and intermodulation performance.
2Reliability
If high tightening torque is applied to achieve adequate contact pressure, then electrical contact is improved, but the complexity of operation and risk of damage increases
Solution Approach 1:
The patent replaces the traditional mechanical tightening system with a spring-based elastic contact system. Instead of relying on high torque to maintain contact pressure, the spring elements provide continuous contact force through their elastic properties, significantly reducing the tightening torque required during assembly and operation.
Solution Approach 2:
The spring mechanism serves itself by automatically maintaining contact pressure through its elastic recovery. Once installed with minimal torque, the spring continuously exerts contact force on the electrical contacts, eliminating the need for high tightening torque and subsequent torque maintenance, thereby simplifying operation.
3Volume of moving object
If compact design is used to reduce connector size, then space requirements are reduced, but capacitive coupling becomes insufficient for high-frequency transmission
Solution Approach 1:
The patent introduces spring elements as intermediary components between the electrical contacts. These springs serve dual functions: maintaining mechanical contact pressure for reliable electrical connection and providing capacitive coupling through their elastic structure, thereby resolving the conflict between compact size and sufficient capacitive coupling for high-frequency transmission.
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 ensures consistent electrical contact and reduced intermodulation, allowing for plug-compatible connectors that maintain performance across various environmental conditions without requiring high torque or material stability.
Implementation Method 1
one of them having an outer conductor contact spring element, via which the outer conductor contact is acted upon in the radial direction with elastic forces
Data Source
Figure 1~2
Figure 2a
Figure 3~4
AI summary
An improved plug connector (100, 200) is characterised by the following features: the electrical outer conductor contacting section of the outer conductor (113, 213) of the plug (100, 200) is designed to run separately in the radial direction from the axial stop, such that the high frequency signal path formed on the inner wall of the outer conductor (113, 213) between the outer conductor (113, 213) of the plug connector (100, 200) and a further outer conductor (213, 113) of a further plug connector (200, 100) for connection thereto runs over the electrical contacting device running in the radial direction and the mechanical action axial stop on the connector or plug side of the plug connector (100, 200) is provided outside the high frequency signal path provided by the radial contacting device.