Pressed Contact Pin Geometry for Stable High-Frequency Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connectors experience signal transmission characteristic deterioration due to corner portion collapses during the punching process, leading to unequal surface lengths and restricted design values, which affect high-frequency signal transmission.
Innovation Solution
The use of a pressing process with a wire rod having a rectangular cross-sectional shape to form contact pins, preventing corner collapses and allowing for equal surface lengths, thereby improving signal transmission characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a punching process is used to manufacture contact pins from a metal plate, then the manufacturing efficiency is improved, but corner portion collapses occur leading to unequal surface lengths and deteriorated signal transmission characteristics
Solution Approach 1:
The patent changes the manufacturing method from punching to pressing, and modifies the raw material form from metal plate to wire rod with rectangular cross-section. This parameter change eliminates corner collapse during manufacturing while maintaining production efficiency, achieving equal surface lengths on all four sides of the contact pin body portion.
2Speed
If a punching process is used to manufacture contact pins, then the manufacturing speed is improved, but the design flexibility is restricted due to corner collapses
Solution Approach 1:
By changing the manufacturing process from punching to pressing and using wire rod material, the patent removes the constraint of corner collapses. This enables greater design flexibility where all four surface lengths can be made equal, allowing contact pins to meet stringent high-frequency signal transmission requirements without compromising manufacturing speed.
3Ease of manufacture
If corner portions are allowed to collapse during punching, then the manufacturing process is simpler, but signal transmission characteristics are deteriorated
Solution Approach 1:
The patent changes the manufacturing parameters from punching to pressing process and from metal plate to wire rod material. This eliminates corner collapse while maintaining process simplicity, ensuring equal surface lengths that provide stable reference potentials and excellent signal transmission characteristics for high-frequency applications.
4Reliability
If equal surface lengths are required for all four sides, then signal transmission characteristics are improved, but the conventional punching process cannot achieve this due to corner collapses
Solution Approach 1:
The patent implements a fundamental parameter change in the manufacturing process (from punching to pressing) and raw material form (from metal plate to wire rod). This enables achievement of equal surface lengths on all four sides of the contact pin, providing stable reference potentials and excellent signal transmission characteristics that cannot be achieved with conventional punching methods.
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 approach stabilizes signal transmission by maintaining equal surface lengths and allowing for a wider range of design options, enhancing the connector's performance in high-frequency bands.
Implementation Method 1
pressing both end portions of a wire rod having a rectangular cross-sectional shape to form the contact pin
Data Source
AI summary
An electrical connector includes a pair of contact pins. Each of the pair of contact pins is obtained by performing a pressing process with respect to a wire rod having a rectangular cross-sectional shape. The contact pin includes a body portion having a rectangular cross-sectional shape. The body portion has an outer surface and an inner surface facing each other, and a third surface and a fourth surface facing each other. The third surface and the fourth surface are perpendicular to the outer surface and the inner surface. The body portion of each of the pair of contact pins further includes a recessed portion formed on the outer surface and a pair of protruding portions respectively protruding from portions of the third surface and the fourth surface adjacent to the recessed portion toward an outer side.