Right-Angled Coaxial Connector Shielding With Stamped Two-Piece Ferrule
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Solution Overview
Problem
Current RF connectors for automotive applications are costly due to the need for strict manufacturing tolerances to ensure proper seating and shielding, which increases costs without providing a low-cost solution that meets performance specifications and improves shielding.
Innovation Solution
A method of forming a right-angled coaxial electrical connector using stamped sheet metal preforms to create a two-piece shield terminal with a tubular shape and semicircular channels, allowing for improved shielding and reduced costs by using a crimped outer ferrule to secure the coaxial cable, while maintaining performance specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If strict manufacturing tolerances are used to ensure proper seating and shielding, then shielding performance is improved, but manufacturing cost increases
Solution Approach 1:
The shield terminal is divided into two separate segments: a first shield terminal segment that crimpes onto the coaxial cable and a second shield terminal segment that interfaces with the mating connector. This segmentation allows each segment to be manufactured with relaxed tolerances independently, eliminating the need for strict tolerances on a single integrated component while maintaining proper shielding through the combined assembly.
2Reliability
If high cost cold drawn tubular shield terminals are used, then shielding performance is improved, but manufacturing cost increases
Solution Approach 1:
The invention replaces expensive cold drawn tubular shield terminals with a stamped shield terminal construction made from sheet material. This cheaper alternative achieves comparable shielding performance through its two-segment design that allows for effective RF shielding without requiring the high manufacturing costs associated with cold drawn tubular components.
3Ease of manufacture
If stamped shield terminals are used to reduce cost, then manufacturing cost decreases, but shielding performance deteriorates
Solution Approach 1:
The stamped shield terminal is divided into two functional segments that work together to achieve proper shielding. The first segment provides cable attachment and local shielding, while the second segment provides connector interface and extended shielding. This segmentation allows the stamped construction to achieve shielding performance comparable to expensive alternatives.
Solution Approach 2:
The two shield terminal segments are nested together in a telescoping arrangement where the first segment fits within or alongside the second segment. This nesting configuration creates an effective shielded enclosure that maintains RF shielding performance while using cost-effective stamped construction methods.
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 provides a low-cost RF connector with improved shielding and reduced signal loss, meeting performance specifications while minimizing manufacturing costs through the use of stamped sheet metal and a crimped outer ferrule for secure coaxial cable attachment.
Implementation Method 1
the first shield terminal portion and the second shield terminal portion are welded together
Implementation Method 2
a crimped outer ferrule to secure the coaxial cable
Data Source
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AI summary
A shielded electrical connector (100) includes a shield terminal attachment segment (104) having a tubular first portion (114) defining a first axis (116) and a first seam (502) and second portion (118) having two channels (504) that extend from the first portion (114) defining a second axis (120) oriented at a right angle to the first axis (116), an inner insulator (204) disposed within the shield terminal attachment segment (104), and a shield terminal connection segment (108) having a tubular third portion having a third axis (122) and a second seam (702) attached to the shield terminal attachment segment (104) where the third axis (122) is coaxial with the first axis (116). Edges of the first seam (502) and edges of the two semicircular channels (504) are joined by the attachment of the shield terminal connection segment (108) to the shield terminal attachment segment (104).