Two-Piece Cavity Insert for RF Connector Assembly

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Solution Overview

Problem

Existing RF connector assemblies face challenges in accommodating various outer contacts within space restrictions while adhering to industry standards, particularly with large cables or contacts assembled on carrier strips, where traditional cavity inserts are not feasible due to size limitations.

Innovation Solution

The development of a two-piece cavity insert with upper and lower shells that couple together, featuring a latching mechanism with straps and catches to securely surround the outer contact, allowing for assembly around the contact without axial loading, thus accommodating different contact sizes and configurations within the connector housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a traditional single-piece cavity insert is used, then the structure is simple, but it cannot accommodate outer contacts with large rear ends or carrier strip configurations due to space restrictions

Engineering Contradiction:

Improveaccommodation of various outer contact configurationsVSAvoidcavity insert structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cavity insert is divided into two separate halves that can be assembled around the outer contact. This segmentation allows the insert to accommodate outer contacts with large rear ends or carrier strip configurations that cannot fit through a single-piece insert, while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the cavity insert is enlarged to accommodate large rear ends of outer contacts, then larger contacts are accommodated, but the housing space restrictions cannot be met

Engineering Contradiction:

Improveaccommodation of large rear end contactsVSAvoidcavity insert size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

By splitting the cavity insert into two halves, the design accommodates large rear end contacts without increasing the overall volume within the housing. The two halves close around the contact from opposite directions, providing the necessary accommodation space while maintaining compact dimensions.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the cavity insert is loaded axially over the outer contact end, then assembly is straightforward, but it is not feasible when the rear end is too large or blocked by carrier strip

Engineering Contradiction:

Improveassembly processVSAvoidcompatibility with various outer contact configurations

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The two-piece cavity insert eliminates the need for axial loading over the outer contact end. Instead, the two halves are positioned on opposite sides of the contact and secured together, providing a feasible assembly method for contacts with large rear ends or carrier strip configurations that block traditional axial loading.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The assembly approach transitions from axial (one-dimensional) loading to a radial/circumferential (two-dimensional) closure method. The two halves of the cavity insert close around the outer contact from opposite directions, providing a new assembly dimension that accommodates configurations incompatible with traditional axial loading.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Reliability

If a two-piece cavity insert with latching mechanism is used, then secure positioning is achieved, but the device complexity increases

Engineering Contradiction:

Improvesecure positioning of contact assemblyVSAvoidcavity insert structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The two-piece cavity insert with latching mechanism achieves secure positioning by dividing the insert into two halves that can be independently positioned and then locked together. This segmentation provides reliable securing of the contact assembly while keeping each individual piece relatively simple in structure.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9787017B1Electrical connector with two-piece cavity insert

Publication Date: 2017.10.10 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

An electrical connector includes an outer contact and a cavity insert. The outer contact has a mating segment, a terminating segment, and a middle segment therebetween. The cavity insert surrounds the middle segment of the outer contact. The cavity insert is defined by an upper shell and a lower shell that couple together at an interface. The upper shell extends along a portion of a perimeter of the outer contact, and the lower shell extends along a remaining portion of the perimeter of the outer contact. The upper shell includes a first strap that extends across the interface. The first strap includes a latching surface that engages a corresponding first catch of the lower shell to couple the upper shell to the lower shell.