Radiator Grounding Element Spring Probe Interconnect
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Solution Overview
Problem
Current interconnection methods for dual-polarized radiators at the K u -band frequency require small feature sizes and tight connector pitches, leading to high labor and piece part costs, potential conductive joint failures, and high insertion forces, while existing methods for assembling PCB arrays with a common RF ground are labor-intensive and not feasible for automated dispensing.
Innovation Solution
The use of plated edges on PCBs and a structural metalized plate with spring probes forming horizontal RF interconnects, along with ground contact achieved through mechanical fasteners or bonding, eliminates the need for solder and manual epoxy dispensing, enabling parallel installation of ground clips and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered interconnects are used, then electrical connection is achieved, but labor cost and piece part cost increase
Solution Approach 1:
The patent replaces the mechanical soldering process with a mechanical press-fit interconnection system. The connector features a body with a cavity that receives a plug, which is then secured through mechanical pressing rather than thermal soldering. This substitution eliminates the need for soldering equipment and skilled labor while maintaining reliable electrical connection through the mechanical press-fit interface.
2Strength
If epoxy bonds are used at each element site, then connection is secured, but labor cost increases and potential failure points are created
Solution Approach 1:
The patent replaces the chemical epoxy bonding process with a mechanical press-fit system. The connector body and plug are designed with complementary geometries that allow direct mechanical insertion and securing through pressing forces. This eliminates the need for epoxy dispensing equipment, curing processes, and associated labor while creating a more reliable connection without chemical joints.
3Adaptability or versatility
If individual cables are assembled for each interconnection, then connection flexibility is achieved, but assembly time and labor cost increase
Solution Approach 1:
The patent merges multiple separate cable assemblies into a single integrated connector system. The connector body contains multiple cavities that receive multiple plugs simultaneously, allowing all interconnections to be established through one unified assembly operation rather than individual cable assemblies. This integration maintains connection flexibility while dramatically reducing assembly time and labor requirements.
4Reliability
If silver epoxy is dispensed along all internal corners of eggcrate structures, then grounding is achieved, but automated dispensing becomes infeasible
Solution Approach 1:
The patent replaces the automated dispensing of silver epoxy along complex internal corners with a mechanical press-fit grounding system. The connector design incorporates grounding features that are mechanically formed through the pressing operation itself, eliminating the need for dispensing equipment to navigate complex geometries. The grounding is achieved through direct metal-to-metal contact established by the press-fit mechanism, which is inherently automatable.
5Manufacturing precision
If small feature sizes and tight connector pitch are used, then K u -band frequency requirements are met, but insertion forces become very high
Solution Approach 1:
The patent incorporates dynamic elements into the press-fit connector design to manage insertion forces. The connector body and plug feature flexible or resilient components that allow gradual engagement during insertion, distributing the force over time and distance rather than requiring a single high-force impact. This dynamic approach enables the tight tolerances required for K u -band operation while keeping insertion forces at manageable levels.
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 solution reduces labor costs, eliminates potential failures from solder joints, and allows for efficient factory throughput by eliminating the need for specialized tools, while providing secure RF connections and design tuning capabilities.
Implementation Method 1
plated edges on PCBs and a structural metalized plate with spring probes forming horizontal RF interconnects
Implementation Method 2
ground contact achieved through mechanical fasteners or bonding
Data Source
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AI summary
A radiator includes an aperture plate defining multiple slots in first and second transverse directions, spring probes disposed within each of the multiple slots, printed circuit boards (PCBs) each having major and minor surfaces and being recessed on either side of multiple portions of one of the minor surfaces to define multiple pads plated with conductive pad material electrically interconnected with a PCB circuit and a grounding element. Each of the PCBs is disposed with the corresponding one of the minor surfaces inserted into a slot such that the PCBs form a crisscrossing pattern and the pads form horizontal blind-mate contacts with the spring probes that are in-plane with corresponding PCB planes. The grounding element is interposed between crisscrossing PCB pairs at complementary notches thereof.