Spring-Embedded Blind Mate Connector for RF Reliability

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Solution Overview

Problem

Reliable RF connections in blind mate radar systems are challenging due to tight lattice spacing and space-constrained packaging, which precludes certain spring-based solutions and results in tolerance buildup and misalignment issues.

Innovation Solution

A spring-embedded blind mate connector assembly with a shared structural load and alignment features across multiple connectors, utilizing a spring with a decreased diameter to accommodate axial misalignment while maintaining sufficient clearance, allowing for reliable mating across expected conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional spring-based solutions are used in blind mate connectors, then connection reliability can be improved, but the connector size increases and cannot accommodate tight lattice spacing

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent changes the critical parameter of spring diameter, using a decreased diameter spring that fits within the tight lattice spacing constraints while still providing the necessary connection reliability. This parameter modification allows the spring to occupy less space without sacrificing its functional performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The spring is nested within the captivator structure, with the decreased diameter spring fitting inside the captivator's outer diameter. This nesting arrangement allows the spring mechanism to be compact while maintaining its reliability function, effectively hiding the spring-based solution within the overall connector geometry.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Volume of moving object

If tighter lattice spacing is used to reduce connector size, then space constraints are satisfied, but tolerance buildup and misalignment issues increase

Engineering Contradiction:

Improveconnector sizeVSAvoidalignment precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The spring acts as a cushioning element that compensates for tolerance buildup and misalignment before connection is established. The spring's compliance absorbs dimensional variations and misalignments that would otherwise prevent reliable connection in tight lattice spacing configurations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The spring introduces dynamic compliance to the connector assembly, allowing it to adapt to misalignment and tolerance variations through elastic deformation. This dynamic characteristic enables the rigid lattice structure to accommodate manufacturing variations without compromising connection reliability.

Inventive Principle:

Principle #15Dynamics

3Volume of moving object

If decreased diameter spring is used to fit tight lattice spacing, then connector compactness is improved, but spring clearance and effectiveness may be reduced

Engineering Contradiction:

Improveconnector compactnessVSAvoidspring clearance

Core Design Contradiction:

Volume of moving objectVSLength of moving object

Solution Approach 1:

The patent carefully modifies the spring diameter parameter to be decreased while maintaining adequate clearance. The spring's outer diameter is reduced to fit within the captivator, but the length and coil spacing are optimized to ensure sufficient active clearance for effective connection and misalignment compensation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The design shifts the clearance requirement from the radial dimension to the axial dimension. By reducing the spring's radial size (outer diameter) to fit within the captivator, the patent compensates by ensuring adequate axial clearance and length, effectively trading radial space for axial space to maintain spring effectiveness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 reliable RF connections by accommodating misalignment and reducing tolerance buildup, ensuring consistent performance in space-constrained environments.

Implementation Method 1

a spring circumscribing the connection extension and embedded between the captivator and the first side of the spring-embedded blind mate connector block, the spring being in abutting relationship with the captivator and the first side of the spring-embedded blind mate connector block

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11381044B2Blind mate connector block and systems and methods thereof

Publication Date: 2022.07.05 LOCKHEED MARTIN CORP

AI summary

A connector block comprised of a plurality of spring-embedded blind mate connector assemblies. Each of the spring-embedded blind mate connector assemblies can be comprised of a first connector extending in a first direction and a second connector extending in a second direction opposite the first direction, where the first connector and the second connector can have a common axis and can be operatively coupled to pass a signal between opposite ends of the spring-embedded blind mate connector assembly. The first connector can include a captivator, a connection extension, and a spring between the captivator and the second connector, where the spring can abut the captivator and have an outer diameter no greater than an outer diameter of the captivator.