Right-Angle Coaxial Connector Deflectable Pin Beams
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Solution Overview
Problem
The assembly of right-angle coaxial connector assemblies is challenging due to tolerances and overstress, leading to unreliable electrical connections and potential damage to contacts.
Innovation Solution
A coaxial connector assembly design featuring a housing with a dielectric holder that includes a mating segment and a cable segment orthogonal to each other, with deflectable pin beams and flared lead-in tips to ensure secure mating and reduce overstress, aligned with the cable axis to receive a pin contact, and a guide opening to facilitate proper alignment and reduce stubbing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional right-angle coaxial connector assemblies are used, then the cable is positioned 90° to the mating axis, but reliable mating of contacts is difficult due to tolerances and overstress
Solution Approach 1:
The pin beams are made deflectable rather than rigid, allowing them to dynamically adjust during the mating process. This deflection capability absorbs tolerances and prevents overstress, enabling reliable electrical connections in the right-angle configuration while maintaining manufacturing feasibility
Solution Approach 2:
The pin beams are designed with varying thickness parameters - thinner at the beam portion to enable deflection and thicker at the base for structural support. This parameter variation allows the contact to be both flexible during mating and stable when connected, resolving the reliability issue in right-angle connectors
2Shape
If conventional right-angle coaxial connector assemblies are used, then the cable is positioned 90° to the mating axis, but the contacts are susceptible to stubbing and damage
Solution Approach 1:
The deflectable pin beams act as a cushioning mechanism that anticipates and absorbs mating misalignments before they can cause damage. The beams deflect outward to accommodate tolerances, preventing stubbing and damage to the contacts while maintaining the right-angle shape
Solution Approach 2:
The varying thickness of the pin beams - thinner for flexibility and thicker at the base for strength - provides both the cushioning effect during mating and the structural strength needed to prevent damage, allowing the right-angle configuration to be both durable and manufacturable
3Shape
If multiple contacts are mated within right-angle assembly, then the cable position is achieved, but assembly is difficult due to tolerances and overstress
Solution Approach 1:
The deflectable pin beams dynamically adapt during assembly, automatically compensating for tolerances without requiring precision alignment. This makes the right-angle connector much easier to manufacture and assemble compared to conventional rigid designs, while still achieving the required 90° cable position
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 design enables reliable and cost-effective assembly of right-angle coaxial connectors with improved electrical connections by deflecting pin beams outward to engage the pin contact, reducing inductive stubbing and accommodating misalignment, thus enhancing the reliability and durability of the connector assembly.
Implementation Method 1
The center contact has deflectable pin beams extending from the base configured to deflect outward when mated with the pin contact
Data Source
AI summary
A coaxial connector assembly includes a housing holding an outer contact and a dielectric holder received in the outer contact. The dielectric holder has a mating segment having a front cavity and a cable segment having a cable cavity receiving a cable assembly. The cable assembly has a pin contact. A center contact is received in the front cavity of the dielectric holder. The center contact has a base positioned in the dielectric holder generally at an intersection of the front cavity and the cable cavity. The center contact has deflectable pin beams extending from the base. The pin beams have flared lead-in tips at distal ends of the beams. The base and the pin beams are axially aligned with the cable axis to receive the pin contact.