RF Socket Contact with Odd Cantilevered Beams
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Solution Overview
Problem
Existing socket contacts face challenges in high-volume, low-cost manufacturing due to inefficient fabrication processes, such as the screw machine process, which generates significant scrap material and is time-consuming, and cut and formed processes that result in either long and space-occupying or fragile arms.
Innovation Solution
A socket contact design featuring a body with an odd number of cantilevered deflectable beams that extend from a central base, defining a socket with a mating zone for receiving a mating pin, where the beams have curved interior surfaces with varying arc lengths to ensure efficient electrical connection and structural asymmetry accommodation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a screw machine process is used to fabricate socket contacts, then manufacturing precision can be achieved, but a relatively large amount of scrap material is generated and fabrication time increases
Solution Approach 1:
The patent changes the manufacturing process parameter from screw machine machining to cut and formed process, which fundamentally alters how the socket contact is created. This parameter change enables high-volume production with reduced material waste while maintaining manufacturing precision through the forming process that shapes the metal blank into the final configuration with minimal scrap.
2Manufacturing precision
If a screw machine process is used to fabricate socket contacts, then manufacturing precision can be achieved, but fabrication time increases
Solution Approach 1:
The patent changes the manufacturing process parameter from screw machine machining to cut and formed process. This parameter change enables high-volume production with reduced fabrication time while maintaining manufacturing precision through the forming process that efficiently shapes the metal blank into the final socket contact configuration.
3Loss of substance
If only two arms are provided in a cut and formed socket contact, then material usage is reduced, but the arms become relatively long and occupy more space
Solution Approach 1:
The patent applies asymmetry by providing socket contacts with different numbers of arms (two, three, or four arms) depending on the specific application requirements. This asymmetric design allows optimization of material usage while controlling the space occupied by the arms, as the odd number of arms creates a more compact configuration compared to symmetric two-arm designs.
4Strength
If four arms are provided in a cut and formed socket contact, then structural support is improved, but the arms become relatively narrow and fragile
Solution Approach 1:
The patent applies asymmetry by providing socket contacts with different numbers of arms (two, three, or four arms) depending on the specific application requirements. This asymmetric design allows optimization of structural support while managing arm fragility, as the odd number of arms creates a more compact configuration with potentially broader arm structures compared to four-arm designs.
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 design allows for efficient, high-volume manufacturing with reduced material usage and scrap, while providing a compact and robust structure that can conduct radio waves, offering improved performance over traditional methods by using a cut and formed process with deflectable beams that are less fragile and occupy less space.
Implementation Method 1
The body has an odd number of cantilevered deflectable beams that extend lengths outward from the base along the central longitudinal axis. The beams define a socket therebetween that is configured to receive the RF mating pin therein. The beams include a mating zone within the socket where the beams mate with the RF mating pin.
Data Source
AI summary
A radio frequency (RF) socket contact is provided for mating with an RF mating pin. The RF socket contact includes a body having a base that extends a length along a central longitudinal axis. The body has an odd number of cantilevered deflectable beams that extend lengths outward from the base along the central longitudinal axis. The beams define a socket therebetween that is configured to receive the RF mating pin therein. The beams include a mating zone within the socket where the beams mate with the RF mating pin. The body of the socket contact is configured to conduct radio waves.