Float Adapter for RF Connectors with Segmented Insulator
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Solution Overview
Problem
Conventional RF connectors lack flexibility in axial and radial float, leading to increased size and higher costs, making them less suitable for high-density applications where smaller, more flexible connectors are required.
Innovation Solution
A float adapter with a conductive shell and insulators that provide modular add-on float capability, featuring a bi-gender bullet with a pyramid-shaped lead-in geometry, allowing for both high and low float configurations without altering the gender of the connectors, and a retaining sleeve for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional RF connector designs are used, then connector size is reduced, but axial and radial float capability is limited
Solution Approach 1:
The connector is divided into modular components including a conductive shell, insulator, inner contact, and retaining sleeve. The insulator is segmented with a reduced diameter middle portion that enables both axial and radial float while maintaining electrical connection. This segmentation allows independent optimization of each component for compact size and float capability.
Solution Approach 2:
The connector design incorporates dynamic float capability through the insulator's reduced diameter middle portion, which allows controlled axial and radial movement between connectors. The retaining sleeve provides elastic retention that permits dynamic adjustment while maintaining secure connection, enabling the system to adapt to manufacturing tolerances and thermal expansion.
2Quantity of substance
If connector density is increased, then physical space is reduced, but manufacturing complexity increases
Solution Approach 1:
The float adapter design serves multiple functions: it provides axial float, radial float, electrical insulation, mechanical retention, and alignment guidance. The retaining sleeve both secures the insulator and allows float movement. This multi-functionality reduces the number of separate components needed, simplifying manufacturing while enabling high connector density.
Solution Approach 2:
The connector components are nested within each other: the inner contact is received in the insulator, which is received in the conductive shell, which is retained by the sleeve. This nested arrangement maximizes space utilization and enables high connector density while maintaining a simple assembly process where components are inserted in sequence.
3Adaptability or versatility
If float capability is improved, then connector flexibility is increased, but connector size increases
Solution Approach 1:
The insulator features a reduced diameter middle portion that concentrates the float capability in a specific local region rather than requiring the entire connector to be larger. This localized design allows axial and radial float while maintaining a compact overall connector volume suitable for high-density applications.
Data Source
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AI summary
A float adapter 1500 for an electrical connector that includes a conductive shell 1502 that has opposite first 1510 and second 1512 ends, and at least one insulator 1504 received in the conductive shell 1502. The at least one insulator 1504 has an engagement end 1530 and an interface end 1532 opposite the engagement end 1530. The interface end 1532 has a lead-in tip portion 1538 that extends outside of one of the first and second ends of the shell 1502. The at least one insulator 1504 has an inner bore 1536 for receiving an inner contact 1506. A retaining sleeve 1524 is disposed around the conductive shell 1502, the retaining sleeve 1524 having an engagement member 1552 for engaging the at least one insulator 1504.