Right-Angle Coaxial Connector Assembly for Low RF Leakage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing RF connectors for automotive applications face challenges in achieving low cost while maintaining proper seating to prevent RF leakage and meeting signal loss and contact resistance specifications, particularly when using stamped shield terminals.
Innovation Solution
A method of forming a shielded electrical connector involves cutting and shaping metal preforms into tubular segments with angled channels, inserting an insulator, and attaching these segments to form a two-piece shield terminal that ensures proper alignment and sealing, using a crimped outer ferrule for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamped shield terminals are used to reduce cost, then manufacturing cost decreases, but shielding performance and seating precision deteriorate
Solution Approach 1:
The shield terminal is divided into two separate segments: a first shield terminal segment and a second shield terminal segment. Each segment can be independently formed from stamped metal preforms, allowing cost-effective manufacturing while maintaining proper seating when assembled together. The segmentation enables each piece to be optimized for its specific function while keeping production costs low.
Solution Approach 2:
The two shield terminal segments are nested within a common insulator body, with each segment positioned in a dedicated cavity. This nesting arrangement ensures proper alignment and seating of the segments within the insulator, maintaining shielding performance while allowing the segments to be manufactured separately at lower cost.
2Ease of manufacture
If stamped shield terminals are used instead of cold drawn tubular terminals, then manufacturing cost decreases, but shielding performance deteriorates
Solution Approach 1:
The shield terminal is segmented into two separately stamped pieces that are assembled within the insulator. This segmentation allows the use of cost-effective stamped terminals while the precise assembly process ensures proper electrical contact and shielding, preventing RF leakage.
Solution Approach 2:
The insulator body acts as an intermediary structure that receives and positions both shield terminal segments. The insulator ensures proper alignment and electrical contact between the segments and the coaxial cable shield, maintaining shielding effectiveness despite the use of stamped terminals.
3Object-affected harmful factors
If strict manufacturing tolerances are applied to ensure proper seating, then shielding performance improves, but manufacturing cost increases
Solution Approach 1:
Dividing the shield terminal into two segments allows each segment to be manufactured with relaxed tolerances individually, while the assembly process within the insulator ensures proper final seating. This eliminates the need for extremely tight tolerances on single-piece terminals, reducing manufacturing cost.
Solution Approach 2:
The insulator structure itself provides the alignment and positioning features needed for proper seating of the shield terminal segments. The insulator cavities and geometric features guide the segments into correct positions during assembly, eliminating the need for expensive precision machining or tight tolerances on the terminal segments.
Data Source
AI summary
A shielded electrical connector includes a shield terminal attachment segment having a tubular first portion defining a first seam and second portion having two semicircular channels that extends from the first portion oriented at a right angle to the first axis, an inner insulator disposed within the shield terminal attachment segment, and a shield terminal connection segment having a tubular third portion and a second seam formed separately from the shield terminal attachment segment and attached to the shield terminal attachment segment such that the third portion is coaxial with the first portion. Edges of the first seam and edges of the two semicircular channels are joined by the attachment of the shield terminal connection segment to the shield terminal attachment segment. A method of forming the shielded electrical connector is also provided.