RF Contact Member Structure for High-Density Closed Entry Mating
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Solution Overview
Problem
Current RF interconnect systems, such as the FAKRA standard, are limited by size and frequency range, failing to support high-density and high-frequency requirements for emerging technologies like autonomous driving and 5G wireless networks, which necessitate smaller, higher-density connectors with improved frequency capabilities.
Innovation Solution
A contact member for electrical connectors is designed with a compact outer conductor, a protective insulator, and a sleeve, featuring spring fingers and longitudinal spokes for robust closed entry mating, deformable termination sections, and impedance-matching geometry, enabling higher frequency and density capabilities while providing mechanical protection and low mating force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the connector size is reduced to achieve higher density packaging, then the density increases, but the frequency range capability deteriorates
Solution Approach 1:
The contact member is divided into distinct functional sections: a mating interface section with spring fingers for connection, a middle section with controlled impedance geometry for signal transmission, and a termination section for cable attachment. This segmentation allows each section to be optimized independently for its specific function while maintaining overall high-frequency performance in a compact form.
Solution Approach 2:
Different sections of the contact member have different geometric properties tailored to their specific functions. The middle section features controlled impedance geometry with specific dimensional relationships to maintain characteristic impedance for high-frequency signals, while the mating interface section has spring fingers for mechanical connection. This local optimization enables high-frequency capability in a compact connector.
2Reliability
If the connector is designed for closed entry mating, then the mechanical protection improves, but the manufacturing complexity increases
Solution Approach 1:
The protective insulator is received within the outer conductor, and the inner conductor is received within the protective insulator, creating a nested structure. This nesting provides closed entry mating protection while using simple cylindrical geometries that are relatively easy to manufacture through conventional drawing or extrusion processes.
Solution Approach 2:
The outer conductor and protective insulator are designed to be received together as an assembly, with the insulator fitting within the conductor. This merging of components provides mechanical protection and closed entry mating capability while reducing the number of separate manufacturing steps compared to assembling multiple discrete parts.
3Ease of operation
If spring fingers are added to the mating interface, then the ease of operation improves, but the device complexity increases
Solution Approach 1:
The spring fingers are designed to be resilient and movable, allowing them to flex during the mating process to accommodate dimensional variations and reduce mating force. This dynamic capability improves ease of operation while the spring fingers are formed as an integrated part of the outer conductor, minimizing additional complexity.
Solution Approach 2:
The spring fingers are formed as thin, flexible resilient elements that can deflect during mating. This flexibility provides ease of operation by reducing mating force requirements, while the spring fingers are created through conventional forming processes that add minimal complexity to the overall structure.
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
The solution enhances the performance of RF connectors by enabling higher frequency operation, improved ergonomics, and mechanical protection, addressing the limitations of existing standards by providing a compact, high-density, and high-frequency capable connector suitable for advanced automotive and wireless applications.
Implementation Method 1
The front end of the outer conductor includes a plurality of spring fingers extending over at least part of the end portion of the protective insulator
Implementation Method 2
the termination section is deformable
Data Source
AI summary
A contact member includes, an outer conductor including a mating interface section that includes a front end of the outer conductor, a termination section including a rear end of the outer conductor, and a middle section therebetween joining the mating interface and termination sections; an inner conductor received in the mating interface section; and a protective insulator including a main portion received in the mating interface section of the outer conductor and supporting the inner conductor and including an end portion configured for closed entry mating. The end portion has an end face extending outside of the front end of the outer conductor.