Radio frequency connector

Abstract

An electrical connector includes a connector housing and a core inserted into the connector housing. The core includes a center conductor, a ground conductor, and an insulating spacer disposed between the center conductor and the ground conductor. The core inner component may be manufactured by an additive manufacturing process.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Patent Application No. 63 / 359,477, filed on July 8, 2022. The entire contents of that application are incorporated herein by reference. Background of the Invention Technical Field

[0002] The present invention generally relates to radio frequency (RF) or coaxial board connectors. Description of Related Technology

[0003] Known RF or coaxial board connectors, such as crimp connectors, are typically manufactured as unit components with preset electrical characteristics. As a result, users may find it difficult to properly adjust or impedance match known RF or coaxial board connectors for a particular application. Furthermore, the structure of known RF or coaxial board connectors is difficult to repair, typically requiring complete replacement during maintenance or when internal electrical components fail. Summary of the invention

[0004] The preferred embodiment of the present invention provides an electrical connector comprising a connector housing and a core insertable into the connector housing. At least a portion of the core can be manufactured by an additive manufacturing process.

[0005] Therefore, an electrical connector that is easy to assemble, disassemble and repair can be provided. In addition, since the components of the core can be manufactured by an additive manufacturing process, the core can be easily adjusted or impedance matched for a preset application. The core can also be easily disassembled and replaced with another core for maintenance or to provide different electrical characteristics.

[0006] According to one embodiment of the present invention, an electrical connector may include a connection housing and a core that may be removably inserted into a housing without physically damaging the core, the housing, or both the core and the connector housing.

[0007] The core may include a center conductor, a ground conductor, and an insulating spacer disposed between the center conductor and the ground conductor. The insulating spacer may include a dielectric material. The insulating spacer may include one or more void spaces. The insulating spacer may be provided with a grid structure. At least one of the center conductor and the ground conductor may terminate along the length of the core. The center conductor may include a recess that may receive a pin of the docking connector or a cable when the electrical connector is docked with the docking connector or a cable.

[0008] The center conductor may be at least partially exposed on the surface of the core that interfaces with the substrate. When the electrical connector interfaces with the docking connector or cable, the grounding conductor may be at least partially exposed on the surface of the core that interfaces with the docking connector or cable. When the electrical connector interfaces with the substrate, the grounding conductor may be at least partially exposed on the surface of the core that interfaces with the substrate. The portion of the grounding conductor that may be at least partially exposed includes a cutout or a recessed portion. The electrical connector may include a ridge located within a port of a connector housing. The core may include a bevel that interfaces with the ridge when the core is inserted into the connector housing.

[0009] According to one embodiment of the present invention, a method for manufacturing a core of an electrical connector may include the following steps: forming a portion of the core by an additive manufacturing process, and placing the portion of the core into a housing.

[0010] The additive manufacturing process may include forming a center conductor, an insulating spacer, and a ground conductor. The insulating spacer may be located between the center conductor and the ground conductor. The insulating spacer may be formed by one or more void spaces. The void spaces may be formed or defined by a grid or matrix structure. The insulating spacer may provide a preset dielectric constant. At least one of the center conductor and the ground conductor may be terminated along the length of the core.

[0011] According to one embodiment of the present invention, a radio frequency crimp connector may include a housing and a removable and insertable signal conductor located in the housing.

[0012] According to one embodiment of the present invention, a radio frequency crimp connector may include a housing and a core, wherein the core may be detachably inserted into the housing without damaging the housing or the core.

[0013] According to one embodiment of the present invention, a radio frequency crimp connector may include a housing and a field repairable core.

[0014] According to one embodiment of the present invention, a radio frequency crimp connector may include a housing, a center conductor, and a dielectric spacer. The center conductor and the dielectric spacer may be manufactured by three-dimensional printing in a single printing process or a single printing procedure.

[0015] The above and other features, elements, characteristics, steps and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a perspective top view of an RF connector mounted on a substrate.

[0017] Figure 2 yes Figure 1 Cross-sectional view of the RF connector and substrate shown.

[0018] Figure 3 yes Figure 1 A top view of the RF connector shown.

[0019] Figure 4 yes Figure 1 A perspective top view of the substrate is shown.

[0020] Figure 5 Yes, the core is inserted Figure 1 A perspective top view of the core of the RF connector is shown.

[0021] Figure 6 yes Figure 5 A perspective bottom view of the core is shown.

[0022] Figure 7 yes Figure 5 A cross-sectional view of the core is shown.

[0023] Figure 8 yes Figure 5 The core shown is inserted Figure 1 A perspective top view of the RF connector shown.

[0024] Fig. 9 yes Figure 5 The core shown is inserted Figure 1 A perspective bottom view of the RF connector shown.

[0025] Fig.10 is a perspective view of a locating pin that can be inserted into Figure 1 RF connector shown.

[0026] Fig.11 and Fig.12 yes Fig.10 The dowel pin shown is inserted into Figure 1 Top and bottom cross-sectional views of the RF connector shown.

[0027] Fig.13 and Fig.14 yes Figure 1 The RF connector shown is installed in Figure 1 A top perspective view of the substrate is shown. DETAILED DESCRIPTION

[0028] Figure 1 is a perspective top view of the RF connector 10 mounted on the substrate 50, Figure 2 A cross-sectional view showing the RF connector 10 and the substrate 50 is shown. Figure 3is a top view of the RF connector 10. The RF connector 10 may be, but is not limited to, a vertically mounted RF connector 10.

[0029] like Figure 1-3 As shown, the RF connector 10 may include a connector housing 12. The connector housing 12 may further include a connector base 14. The connector housing 12 and the connector base 14 may be integral, or manufactured, machined, or cast as a single component, and may be made of a conductive material, such as metal. The connector housing 12 may include an external thread 16 adjacent to at least one port 18 of the RF connector 10. The connector housing 12 or the connector base 14 may include at least one or at least two connector fastening holes 20. As described below, the RF connector 10 may also include a ridge 19 as an alignment feature.

[0030] Figure 4 yes Figure 1 50 is a perspective top view of the substrate 50. Figure 1-4 As shown, the RF connector 10 can be fixed to the substrate 50 by screws 22 or similar components inserted through the substrate fastening holes 58 and received by the connector fastening holes 20. The substrate 50 further includes a signal trace 52 and one or more ground traces 54. Although Figure 1 and Figure 4 Two ground traces 54 are shown to be arranged in parallel with the signal trace 52 located therebetween, but the substrate 50 is not limited to this particular arrangement. The ground traces 54 are connected to a ground plane 56, which can be in contact with the conductive material of the connector housing 12. Although the signal traces 52, the ground traces 54, and the ground plane 56 are shown as being provided on the outer surface of the substrate 50, one or more of the signal traces 52, the ground traces 54, and the ground plane 56 can be included in the outer surface of the substrate 50 or extend below the outer surface of the substrate 50.

[0031] Figure 5-7 Shows insertable Figure 1 The core 30 of the RF connector 10 is shown in perspective and cross-sectional views. The core 30 includes a center conductor 31 that passes through the core 30 and can be configured to conduct electrical signals, and also includes a ground conductor 35 that surrounds the center conductor 31 in a coaxial arrangement and can be connected to a ground line. One end of the core 30 can include a connector interface pin 32, which can be provided by a recess in the center conductor 31. The connector interface pin 32 can receive a pin or cable from a mating connector, such as a coaxial cable.

[0032] The center conductor 31 may be surrounded by one or both of the dielectric spacer 33 and the void space 34. The dielectric spacer 33 and the void space 34 may electrically isolate the center conductor 31 from the ground conductor 35. The dielectric spacer 33 and the void space 34 may have a grid structure. Figure 5 As shown, the dielectric spacer 33 may include four spokes extending between the center conductor 31 and the shell 39 of the core 30, but the dielectric spacer 33 may include any number of spokes. The structure of the dielectric spacer 33 and the void space 34 and the material composition of the dielectric spacer 33 can be adjusted to provide a predetermined electrical property, such as a predetermined dielectric constant. The ground conductor 35 can surround the center conductor 31, and the ground conductor 35 can be at least partially surrounded by the shell 39. The shell 39 can be plastic or other non-conductive material.

[0033] The ground conductor 35 may be provided with both a connector ground portion 36 and a substrate ground portion 37 at different ends of the core 30, wherein the connector ground portion 36 and the substrate ground portion 37 are at least partially not covered by the housing 39. The connector ground portion 36 may be provided with a planar shape capable of docking with a corresponding ground connection of a docking connector or cable. The substrate ground portion 37 may be provided with a planar shape capable of docking with the ground plane 56 of the substrate 50. The substrate ground portion 37 may also include a core grounding cutout 38 in the substrate ground portion 37, as described below with respect to Fig. 9 Further discussion.

[0034] As shown in FIG7 , one or more of the center conductor 31, the dielectric spacer 33, the void space 34, and the ground conductor 35 may have a terminal shape along the length of the core 30. In particular, providing a terminal shape in the assembly of the core 30 helps prevent reflections. However, the shapes of the elements of the core 30 are not limited to the shapes shown in the figure, and can be modified according to predetermined electrical characteristics, such as predetermined impedance characteristics, etc. One or more of the center conductor 31, the dielectric spacer 33, the ground conductor 35, and the housing 39 can be made by an additive manufacturing process, such as a three-dimensional printing process and / or a laser printing process.

[0035] Figure 8 and Fig. 9 yes Figure 5 The core is inserted Figure 1 A perspective view of the RF connector 10 is shown.

[0036] like Figure 8As shown, the core 30 can be inserted into the RF connector 10 via the port 18, wherein the connector interface pins 32 and the connector grounding portion 36 are exposed at the port 18. Accordingly, the docking connector or cable can be electrically connected to the connector interface pins 32 and the connector grounding portion 36 of the core 30, and the docking connector or cable can be physically fixed to the RF connector 10 through the external thread 16. Therefore, the RF connector 10 and the core 30 can be provided with but not limited to a vertically mounted RF crimp connector. The port 18 can be located at the upper portion of the RF connector 10 so that the core 30 can be inserted into the RF connector 10 at the top of the RF connector 10. The length of the core 30 can be approximately equal to the height of the RF connector 10. However, the length of the core 30 is not limited and can be shorter or longer than the length of the RF connector 10.

[0037] like Figure 5 and Figure 6 As shown, the core 130 may include a chamfer 40 as an alignment feature. When the core 30 is inserted into the RF connector 10, the core 130 will align only when the chamfer 40 is aligned with the ridge 19 (e.g., Figure 3 The core 30 can be fully inserted into the RF connector 10 only when the core 30 is aligned (as shown). The core 30 can be fixed to the RF connector 10 by, for example, a press-fit connection, a press-fit and twist connection, an interference fit, glue, an adhesive, or a retention feature provided on the housing 39.

[0038] like Fig. 9 As shown, the RF connector 10 may further include a base grounding notch 28, and when the core 30 is inserted into the RF connector 10, the base grounding notch 28 may be aligned with the core grounding notch 38. The core grounding notch 38 and the base grounding notch 28 provide a path for the signal trace 52 of the substrate 50 (such as Figure 1 , 2 and 4).

[0039] At least a portion of the substrate ground portion 37 may include a roughened surface or stress concentrators, such as bumps or pyramid shapes formed on the substrate ground portion 37. The roughened surface or stress concentrators may provide improved conductivity between the substrate ground portion 37 and the ground plane 56 by providing multiple physical and electrical connection points between the substrate ground portion 37 and the ground plane 56.

[0040] According to the structure of the RF connector 10 and the core 30, an electrical connector, such as the RF connector 10, can be provided, which can be easily assembled, disassembled and repaired. For example, the core 30 can be repaired, replaced or repaired on site, and there is no need to send the RF connector 10 or the core 30 back to the manufacturer or the like, and there is no need to remove or disconnect the RF connector 10 from the docking substrate or the main circuit board, such as the substrate 50. In addition, since the core 30 can be manufactured by an additive manufacturing process, it can be easily tuned or impedance matched to be suitable for a preset application. The core 30 can also be easily disassembled and replaced with another core for maintenance or to provide different electrical characteristics. For example, if the system impedance changes, the core 30 can be disassembled and replaced with a new core 30 with different impedance without reinstalling a new connector on the substrate or the main circuit board. In addition, since the impedance can be adjusted or set according to the core 30, the RF connector 10 does not need to be processed during the manufacturing process.

[0041] The RF connector 10 may include only a single step, and the internal width of the RF connector 10 between the step and the mating substrate or main circuit board 50 may be constant or substantially constant. More than 60%, more than 70%, more than 80%, more than 90%, or more than 95% of the length of the center conductor 31 may be at least partially surrounded by the housing 39. In other words, the housing 39 may extend along the entire longitudinal length of the center conductor 31, may extend along at least 95% of the entire longitudinal length of the center conductor 31, may extend along at least 90% of the entire longitudinal length of the center conductor 31, may extend along at least 75% of the entire longitudinal length of the center conductor 31, or may extend along at least 50% of the entire longitudinal length of the center conductor 31.

[0042] FIG. 10 is a perspective view of a positioning pin 70 that may be inserted into the RF connector 10 or connector housing 12 shown in FIG. 1 . Fig.11 and Fig.126 is a top and bottom cross-sectional view of the locating pin 70 inserted into the RF connector 10. The locating pin 70 may include a body 72 and an embossed portion 76. The body 72 may be made of plastic or a dielectric material and may include a shape corresponding to the internal space of the connector base 14 of the RF connector 10. The embossed portion 76 is provided with a protrusion protruding from the body 76, which may be semicircular or in other shapes that can be connected to the signal trace 52 and the ground plane 56 of the substrate 50 or the isolation pad AP space between the isolation pads AP. That is, the raised embossed portion 76 can engage with the traces on the substrate 50 and the space provided between the signal traces and the isolation pads AP. Alternatively, an embossed portion 76 may also be formed at the end of the core 30 (FIG. 6). The RF connector 10 (FIG. 9) may include a housing, such as a connector housing 12 (FIG. 9) and a core 30 (FIG. 9), and the core 30 may be or is configured to be repeatedly inserted and removed from the connector housing 12 without damaging the connector housing 12 or the core 30. The core 30 may further include an embossed portion 76 ( FIG. 10 ) that is configured to engage with the substrate 50 ( Fig.11 ) on the substrate signal trace 52 (FIG. 11) and the associated ground plane 56 (FIG. 11). The core 30 may further include a center conductor 31 (FIG. 7) having an embossed portion 76 (FIG. 10) configured to engage with the substrate signal trace 52 (FIG. 11) on the substrate 50 (FIG. 11) in only one possible direction. Fig.11 ) and a corresponding shape or spatial joint set between the associated ground plane 56 (Figure 11).

[0043] The locating pin 70 may be manufactured by an additive manufacturing process, such as a three-dimensional (3D) printing process. The relief portion 76 may be provided in or on the locating pin 70 by an additive manufacturing process, such as a three-dimensional (3D) printing process or a laser printing process.

[0044] Fig.13 and Fig.14 FIG. 5 is a top perspective view of the RF connector 10 mounted on the substrate 50. Fig.13 As shown, the RF connector 10 is positioned on the substrate 50, and the locating pin 70 is inserted into the RF connector 10. The locating pin 70 is then rotated until the embossed portion 76 engages with the traces on the substrate 50, such as the signal trace 52 and the ground plane 156. Fig.14 As shown, the screw 22 is inserted through the substrate fastening hole 58 and into the connector fastening hole 20. After the locating pin 70 is positioned to properly align the RF connector 10 with the substrate 50, the screw 22 can be tightened to fix the RF connector 10 to the substrate 50. The locating pin 70 can then be removed and the core 30 can be inserted into the RF connector 10, as shown in FIG. Figure 8 and Fig. 9 Since the locating pins 170 can align the RF connector 10 with the substrate 50 , proper alignment between the center conductor 31 of the core 30 and the signal trace 52 of the substrate 50 can be provided.

[0045] Although the present disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and elements therein may be substituted with equivalents without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt specific systems, devices, or components thereof to the teachings of the present disclosure without departing from its basic scope. Therefore, the present disclosure is not intended to be limited to the specific embodiments disclosed for implementing the present disclosure, but includes all embodiments falling within the scope of the appended claims.

[0046] The terms used herein are only used for the purpose of describing specific embodiments and are not intended to limit the present disclosure. In this article, the singular forms of the words "a", "an" and "the" are intended to include the plural forms, unless the context clearly indicates otherwise. It should be further understood that when the terms "include" and / or "comprise" are used in this specification, they specify the presence of the features, integers, steps, operations, elements and / or components described, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations resulting therefrom.

[0047] The description of the present disclosure has been shown for the purpose of illustration and description, but is not intended to be exhaustive or to limit the present disclosure to the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope of the present disclosure. The embodiments described have been chosen and described in order to best explain the principles and practical applications of the present disclosure and to enable those skilled in the art to understand the various embodiments and modifications of the present disclosure as applicable to the particular use contemplated.

Claims

1. An electrical connector, comprising a connector housing; and A core that is removably inserted into a connector housing. 2 . The electrical connector according to claim 1 , wherein the core comprises a center conductor, a ground conductor, and an insulating spacer disposed between the center conductor and the ground conductor.

3. The electrical connector of claim 2, wherein the insulating spacer comprises a dielectric material.

4. An electrical connector according to claim 2 or 3, wherein the insulating spacer comprises one or more void spaces.

5. The electrical connector according to any one of claims 2 to 4, wherein the insulating spacer is provided with a grid structure.

6. The electrical connector according to any one of claims 2-5, wherein at least one of the center conductor and the ground conductor is terminated along the length of the core.

7. The electrical connector according to any one of claims 2 to 6, wherein the center conductor comprises a recessed portion, and when the electrical connector is mated with a mating connector or a cable, the recessed portion receives a pin of the mating connector or a cable.

8. The electrical connector according to any one of claims 2 to 7, wherein when the electrical connector is mated with a substrate, the center conductor is at least partially exposed on a surface of the core mated with the substrate.

9. The electrical connector according to any one of claims 2 to 8, wherein when the electrical connector is mated with a mating connector or a cable, the ground conductor is at least partially exposed on a surface of the core mated with the mating connector or the cable.

10. The electrical connector according to any one of claims 2 to 9, wherein when the electrical connector is mated with a substrate, the ground conductor is at least partially exposed on a surface of the core mated with the substrate.

11. The electrical connector of claim 10, wherein the at least partially exposed portion of the ground conductor comprises a cutout or a recessed portion.

12. The electrical connector according to any one of claims 1 to 11, wherein: The electrical connector includes a ridge positioned within a connector housing port; and The core includes a beveled surface that abuts the ridge when the core is inserted into the connector housing.

13. A method for manufacturing a core of an electrical connector, the method comprising the following steps: forming a portion of the core by an additive manufacturing process; as well as The portion of the core is placed into a casing.

14. The method according to claim 13, wherein: The additive manufacturing process includes forming a center conductor, an insulating spacer, and a ground conductor; and The insulating spacer is located between the center conductor and the ground conductor.

15. The method of claim 14, wherein the insulating spacer is formed with one or more void spaces.

16. The method of claim 15, wherein the void spaces are formed in a grid or matrix structure.

17. The method of any one of claims 14-16, wherein the insulating spacer is formed to provide a predetermined dielectric constant.

18. The method of any one of claims 14-17, wherein at least one of the center conductor and the ground conductor is terminated along the length of the core.

19. A radio frequency crimp connector, comprising: case; as well as Insertable and removable signal conductors are positioned within the housing.

20. A radio frequency crimp connector, comprising: case; as well as A core that can be removed and reinserted into a housing without damaging the housing or the core.

21. A radio frequency crimp connector, comprising: case; as well as Field repairable core.

22. A radio frequency crimp connector, comprising a housing, a center conductor, and a dielectric spacer, wherein the center conductor and the dielectric spacer are both manufactured by three-dimensional printing.

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