RF Connector Arc Protrusions for Rigidity and Flexibility
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Solution Overview
Problem
Existing RF electrical connectors with metallic shells face challenges in achieving superior interengagement between the outer conductor and the metal box, particularly due to bending moments during mating, which affects the connector's rigidity and flexibility.
Innovation Solution
The design features an outer conductor with arc protrusions on its rear face, coaxially arranged with the inner conductor and insulator, and a metal box with corresponding arc holes that provide both interference and clearance fits to enhance the interengagement, offering both rigidity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer conductor is rigidly fixed to the metal box, then the structural strength is improved, but the flexibility during mating is reduced
Solution Approach 1:
The connection between the outer conductor and metal box is segmented into multiple arc protrusions (typically 3-6) distributed around the circumference. Each protrusion can independently engage with corresponding arc holes, allowing partial flexibility while maintaining overall structural strength. This segmentation enables the connection to accommodate bending moments during mating while preserving rigidity in the assembled state.
Solution Approach 2:
Different regions of the connection interface have different engagement characteristics. The arc protrusions are strategically positioned and sized to provide varying degrees of engagement - some regions allow slight movement for flexibility during mating, while other regions provide rigid support for structural strength. This local differentiation of connection quality resolves the contradiction between rigidity and flexibility.
2Adaptability or versatility
If the outer conductor is loosely fitted to the metal box, then the flexibility is improved, but the structural strength is reduced
Solution Approach 1:
The connection is divided into multiple discrete arc protrusions that engage with arc holes. This segmentation allows the structure to be loose enough for flexibility during mating while maintaining sufficient engagement points to provide structural strength when assembled. The distributed arrangement of protrusions ensures both flexibility and strength are achieved simultaneously.
Solution Approach 2:
The connection interface is designed to be dynamic during the mating process, allowing movement and adjustment, but becomes stable and strong in the final assembled state. The arc protrusions enable controlled movement during insertion while providing firm engagement when mated, transitioning from a flexible state to a rigid state as needed.
3Manufacturing precision
If multiple arc protrusions are added to enhance interengagement, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The connection interface is segmented into multiple identical or similar arc protrusions and arc holes. This modular segmentation allows for improved manufacturing precision through standardized components that can be consistently manufactured and assembled. While the number of features increases, the repetition of similar elements actually simplifies the manufacturing process compared to creating unique complex features.
Solution Approach 2:
The arc protrusions serve multiple functions: they provide structural support, enable precise alignment, accommodate bending moments, and facilitate easy assembly. By making these simple geometric features multi-functional, the design achieves high manufacturing precision without proportionally increasing device complexity. The same basic feature (arc protrusion) accomplishes multiple objectives simultaneously.
Data Source
AI summary
An electrical connector includes an outer conductor and an inner conductor coaxially arranged with each other with an insulator therebetween. The outer conductor includes a base and a plurality of arc protrusions formed on a rear face of the base and coaxially sharing the same circle center. The protrusions are optimally located around a peripheral region of the circle defined by the cross-section of the cylindrical contour. A metallic box includes a top wall, opposite front and rear walls and opposite two side walls. The front wall forms a plurality of arc holes coaxially arranged with regard to a common center so as to snugly receive the corresponding arc protrusions of the outer conductor, respectively.