Stamped RF Connector Assembly Impedance Control
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Solution Overview
Problem
Current RF connector assemblies, particularly those following the FAKRA standard, are expensive to manufacture due to the use of zinc die-cast or screw-machined parts, and there is a need for cost-effective and reliable alternatives that can utilize stamped and formed parts without compromising performance.
Innovation Solution
The development of a connector assembly featuring a stamped and formed outer contact and ferrule, where the outer ferrule is crimped to control impedance, and a cavity insert with a flange to secure the subassembly within the outer housing, allowing for the use of less expensive materials while maintaining the necessary shielding and impedance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zinc die-cast or screw-machined parts are used for outer contact and ferrule, then manufacturing precision and reliability are improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive zinc die-cast or screw-machined outer contacts and ferrules with stamped and formed parts made from less expensive materials. The stamped outer contact and formed ferrule maintain functional reliability while significantly reducing manufacturing cost, embodying the principle of using cheaper alternatives that still fulfill the required function.
Solution Approach 2:
The patent modifies the manufacturing parameters and material selection for the outer contact and ferrule components. By transitioning from die-casting or screw-machining processes to stamping and forming processes, and by selecting appropriate materials for these formed parts, the patent achieves cost reduction while maintaining the necessary mechanical and electrical properties.
2Ease of manufacture
If stamped and formed parts are used for outer contact and ferrule, then manufacturing cost is reduced, but manufacturing precision may deteriorate
Solution Approach 1:
The patent employs stamped and formed parts as cost-effective alternatives to precision-machined components. The stamping and forming processes are designed to achieve the required dimensional tolerances for RF connector functionality, demonstrating that cheaper manufacturing methods can meet precision requirements when properly engineered.
Solution Approach 2:
The patent adjusts manufacturing parameters such as stamping pressure, forming temperature, and material selection to optimize the precision of stamped and formed parts. By controlling these parameters, the patent ensures that the cost-effective manufacturing process produces parts with sufficient dimensional accuracy for RF signal transmission.
3Manufacturing precision
If outer ferrule is crimped to control gap size, then impedance control is improved, but device complexity increases
Solution Approach 1:
The patent designs the crimping process to be self-regulating, where the crimping force and geometry automatically control the gap size between the outer contact and ferrule. The crimping tool and ferrule geometry are designed together so that the act of crimping itself achieves the precise impedance control needed, without requiring additional adjustment mechanisms or complex assembly steps.
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 manufacturing costs by using stamped and formed parts while ensuring reliable and efficient signal transmission through the control of impedance, meeting the performance standards of FAKRA connectors for automotive and other applications.
Implementation Method 1
The size of the gap is controllable to control an impedance of the connector
Implementation Method 2
The outer ferrule is crimped to control the size of the gap in the inner ferrule segment
Implementation Method 3
the braid is sandwiched between the outer ferrule and the outer contact
Data Source
AI summary
A connector assembly includes a center contact configured to be terminated to a center conductor of a cable. A dielectric holds the center contact. A stamped and formed outer contact surrounds the dielectric and the center contact. The outer contact is configured to be terminated to a braid of the cable. A stamped and formed outer ferrule surrounds at least a portion of the outer contact such that the braid is sandwiched between the outer ferrule and the outer contact.