3D printed angled coaxial connector
The single-piece conductive housing and dielectric insert manufactured by 3D printing technology, combined with a swept right-angle design, solve the problems of signal integrity and VSWR in right-angle coaxial connector assemblies, and realize connector assemblies with low voltage standing wave ratio and high precision applications at high frequencies.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-23
- Publication Date
- 2026-03-27
AI Technical Summary
Existing right-angle coaxial connector assemblies are inadequate in maintaining signal integrity, especially panel-mount right-angle connector assemblies which are associated with inadequate voltage standing wave ratios (VSWR) and struggle to maintain good performance at high signal frequencies.
The single-piece conductive housing and dielectric insert are manufactured using 3D printing technology. Combined with a swept right-angle design, including an arc-shaped part and a dielectric receiving channel, the center contact is swept at an angle. The dielectric constant is adjusted by adjusting the dielectric material and air ratio to minimize stray capacitance, ensuring impedance matching and signal integrity.
A voltage standing wave ratio (VSWR) of less than 1.2 is achieved at frequencies up to 65 GHz, making it suitable for high-precision and high-density applications and reducing the risk of failure due to shock or vibration.
Smart Images
Figure CN121748893A_ABST
Abstract
Description
Technical Field
[0001] This invention generally relates to coaxial connector assemblies. In particular, this invention relates to an angled coaxial connector assembly that can be mounted onto a substrate. Background Technology
[0002] Right-angle coaxial connector assemblies are commonly used to terminate coaxial cables to circuit boards or panels. However, these connector assemblies often fail to maintain the desired signal integrity. In particular, panel-mount right-angle connector assemblies are often associated with poor voltage standing wave ratios (VSWR).
[0003] Therefore, it would be advantageous to provide an angled coaxial connector assembly in which the internal contacts are angled (including swept right angles) and provide the required VSWR at high signal frequencies. In particular, it would be advantageous to provide an angled coaxial connector assembly that occupies minimal board space and is easy to manufacture. Summary of the Invention
[0004] One embodiment relates to a swept-angle RF connector having a 3D-printed conductive shell formed as a single piece. The conductive shell has a mating connector receiving portion with a mating connector receiving surface and a mounting portion with a mounting surface extending in a plane substantially perpendicular to the plane extending from the mounting surface. An arcuate portion extends between the mating connector receiving portion and the mounting portion. A dielectric receiving channel is disposed in the arcuate portion, the dielectric receiving channel being swept-angled and having a circular cross-section. A dielectric insert is positioned in the dielectric receiving channel. The dielectric insert is swept-angled and has a circular cross-section extending from a first surface near the mating connector receiving portion to a second surface near the mounting portion, the first surface extending in a plane substantially perpendicular to the plane extending from the second surface, and a contact receiving channel extending through the dielectric insert from the first surface to the second surface. A center contact is located in the contact receiving channel, the center contact being swept-angled and having a circular cross-section.
[0005] In one embodiment, the dielectric insert is made of different components. The first component is a solid member extending approximately 180 degrees around the central contact. The second component has a cavity disposed therein and extends approximately 180 degrees around the central contact, the component having a cavity disposed therein.
[0006] In this embodiment, a third component is provided. The third component extends 360 degrees around the central contact.
[0007] In one embodiment, the connector is an ultra-miniature push-up micro RF connector that maintains signal integrity while altering the signal path by 90 degrees with a small bending radius. For signal frequencies up to 65 GHz, the connector's voltage standing wave ratio (VSWR) is less than 1.2.
[0008] Other features and advantages of the invention will become apparent from the following more detailed description of preferred embodiments taken in conjunction with the accompanying drawings, which illustrate the principles of the invention by way of example. Attached Figure Description
[0009] Figure 1 This is a perspective front view of a first illustrative embodiment of the swept right-angle RF connector according to the present invention.
[0010] Figure 2 yes Figure 1 Side view of the connector.
[0011] Figure 3 yes Figure 1 Bottom view of the connector
[0012] Figure 4 It is along Figure 3 The cross-sectional view of the connector is taken from line 4-4.
[0013] Figure 5 yes Figure 4 A perspective view of an illustrative embodiment of the center insert, showing the center contact and the dielectric material surrounding the center contact.
[0014] Figure 6 This is a perspective front view of a second illustrative embodiment of the swept right-angle RF connector according to the present invention.
[0015] Figure 7 yes Figure 6 Side view of the connector.
[0016] Figure 8 yes Figure 6 Bottom view of the connector
[0017] Figure 9 It is along Figure 8 The connector cross-section is shown in line 9-9.
[0018] Figure 10 yes Figure 9 A perspective view of an illustrative embodiment of the center insert, showing the center contact and the dielectric material surrounding the center contact.
[0019] Figure 11 It is shown Figure 1 The VSWR performance of the connector is shown in the graph relative to frequency.
[0020] Figure 12 It is shown Figure 6 The VSWR performance of the connector is shown in the graph relative to frequency. Detailed Implementation
[0021] Figures 1 to 5 The swept right-angle RF connector 10 shown is for mounting onto a substrate or printed circuit board (not shown). Connector 10 includes a conductive or metal housing 12, a dielectric insert 14, and a center pin or contact 16. In the illustrative embodiment shown, the swept right-angle RF connector 10 is an Ultra-Small Push-Up Miniature (SMPM) connector, a blind-mating, push-up connector with a miniaturized size and high (up to 65 GHz) transmission frequency; however, other types of connectors can also be used. SMPM connectors are used in applications requiring high precision, high density, and high speed, such as phased-array radar and board-to-board connections in Mil-Aero and Defense applications. Although a swept right-angle RF connection is shown, RF connectors can have sweep angles or bend angles greater than 0 degrees and less than or equal to 90 degrees.
[0022] The metal housing 12 is formed as a single piece by an additive process (e.g., 3D printing). In the illustrative embodiment shown, the housing 12 is made of metal, but other conductive materials that provide the required shielding can be used. The housing 12 has a mating connector receiving portion 18 with a mating connector receiving surface 20 and a substrate mounting portion 22 with a substrate mounting surface 24. The mating connector receiving surface 20 extends in a plane substantially perpendicular to the plane extending from the substrate mounting surface 24.
[0023] The arc-shaped portion 26 extends between the mating connector receiving portion 18 and the substrate mounting portion 22. A dielectric receiving channel 28 is provided in the arc-shaped portion 26. Figure 4 The dielectric receiving channel 28 extends from the mating connector receiving portion 18 to the substrate mating portion 22. The dielectric receiving channel 28 is a swept right angle or curved shape and has a circular cross-section with a constant radius. However, other configurations may have radii of different sizes. The geometry of the arcuate portion is configured to provide the desired impedance requirement, such as, but not limited to, 50 ohms. Although the arcuate portion 26 is shown as a swept right angle, the arcuate portion may have a sweep angle greater than 0 degrees and less than or equal to 90 degrees, consistent with the angle of the connector 10.
[0024] The dielectric insert 14 can be formed by various methods, including molding or additive processes such as 3D printing. The dielectric insert 14 is made of an insulating material that is a poor electrical conductor. The dielectric insert 14 is configured to be positioned within the dielectric receiving channel 28. Figure 4 and Figure 5As shown, the dielectric insert 14 is in a swept right-angle or curved shape and has a circular cross-section with a constant radius extending from a first surface 30 near the mating connector receiving portion 18 to a second surface 32 near the substrate mounting portion 22. However, other configurations may have radii of different sizes. The first surface 30 extends in a plane substantially perpendicular to the plane extending from the second surface 32. The radius of the dielectric insert 14 is approximately equal to the radius of the insulating receiving channel 28. The dielectric insert 14 is designed to reduce stray capacitance caused by the bending of the center contact 16. Stray capacitance reduces the impedance of the connector. Minimizing stray capacitance allows for higher impedance, for example, closer to a target of 50 ohms in the illustrative embodiment shown. Although the dielectric insert 14 is shown as a swept right-angle, the dielectric insert 14 may have a sweep angle greater than 0 degrees and less than or equal to 90 degrees, consistent with the angle of the connector 10.
[0025] The center contact 16 is made of conductive material and is located in the contact receiving channel 34. The center contact 16 is shaped as a swept right angle or curved and has a circular cross-section with a constant radius. However, other configurations may have radii of different sizes. The radius of the center contact 16 is approximately equal to the radius of the contact receiving channel 34. The center contact 16 has a first straight portion 36 extending into the mating connector receiving portion 18, a second straight portion 38 extending into the substrate mounting portion 22, and an arcuate portion 40 located in the contact receiving channel 34 and extending between the first straight portion 36 and the second straight portion 38. Although the arcuate portion 40 is shown as a swept right angle, the arcuate portion 40 may have a sweep angle greater than 0 degrees and less than or equal to 90 degrees, consistent with the angle of the connector 10.
[0026] Referring again to dielectric insert 14, it can be readily modified to minimize the effects of stray capacitance and improve impedance. In various embodiments, dielectric insert 14 can be adjusted by using a material with a higher or lower dielectric constant. Alternatively, the structure of dielectric insert 14 can be modified.
[0027] exist Figures 1 to 5 In the exemplary embodiment shown, the dielectric insert 14 is made of three parts. In other embodiments, the dielectric insert 14 may have different constructions, such as, but not limited to, a single 3D-printed part.
[0028] like Figure 5 As shown, the first component 42 is a solid member, such as... Figure 5 As can be seen, it is located above the center contact 16. The first component 42 extends approximately 180 degrees around the center contact 16.
[0029] like Figure 5As seen, the second component 44 is located below the center contact 16. The second component 44 extends approximately 180 degrees around the center contact 16. The second component 44 has a cavity 46 disposed therein. In the illustrative embodiment shown, the cavity 46 is a channel or conduit extending through the second component 44, but other configurations may also be used.
[0030] By introducing cavitation 16 to modify the dielectric insert 14, the effective dielectric constant of the dielectric insert 14 becomes a value between the dielectric constants of air and the dielectric material. The dielectric constant can be easily adjusted by changing the ratio of the dielectric material to air, or in other words, by increasing or decreasing the cavitation volume. Furthermore, the dielectric insert 14 can be locally fine-tuned, meaning the cavitation volume is controlled from one location to another within the dielectric insert 14, thus the effective dielectric constant of the dielectric insert 14 is different at different locations to match impedance matching requirements and end with smooth signal transmission. While the illustrative embodiment shows tubular cavitation 46, the second component 44 and the dielectric insert 14 can have other configurations and positioning of cavitation.
[0031] like Figure 5 As can be seen, the third component 48 is located below the first component 42 and the second component 44. The third component 48 extends 360 degrees around the central contact 16.
[0032] The dielectric strengths of the first component 42, the second component 44, and the third component 48 can be the same or varied to provide the desired performance. Furthermore, the sweep angle or curved shape of the connector 10, and the gap between the center pin or contact 16 and the metal housing 12, are constant along the entire length of the arcuate portion 26 of the housing 12, thereby controlling and maintaining a constant impedance throughout its length, making the connector 10 suitable for very high frequencies. Since both the housing 12 and the center contact 16 are formed as a single piece, the risk of connector 10 failing due to shock or vibration is reduced compared to known connectors.
[0033] In the illustrated embodiment, connector 10 is an ultra-small push-to-millimeter (SMPM) RF connector that maintains signal integrity while altering the signal path by 90 degrees with a small bending radius. Figure 11 As shown, for signal frequencies up to 65 GHz, the exemplary connector 10 has a voltage standing wave ratio (VSWR) of less than 1.2, as indicated by curve 50. This allows connector 10 to be used in applications requiring high precision and high density.
[0034] Figures 6 to 10A second exemplary embodiment is shown. In this embodiment, a swept right-angle RF connector 110 is used to connect an RF cable 111 to a mating connector (not shown). The connector 110 includes a first conductive or metal shell 112, a second conductive or metal shell 113, a dielectric insert 114, and a center pin or contact 116. Although a swept right-angle RF connection is shown, the RF connector may have a sweep angle or bend angle greater than 0 degrees and less than or equal to 90 degrees.
[0035] The first metal shell 112 is formed as a single piece by an additive process (e.g., 3D printing). In the illustrative embodiment shown, the shell 112 is made of metal, but other conductive materials that provide the required shielding can be used. The shell 112 has a mating connector receiving portion 118 with a mating connector receiving surface 120 and a cable mounting or receiving portion 122 with a cable mounting or receiving surface 124. The mating connector receiving surface 120 extends in a plane substantially perpendicular to the plane extending from the cable receiving surface 124.
[0036] An arc-shaped portion 126 extends between the mating connector receiving portion 118 and the cable receiving portion 122. A dielectric receiving channel 128 is provided in the arc-shaped portion 126. The dielectric receiving channel 128 extends from the mating connector receiving portion 118 to the cable receiving portion 122. The dielectric receiving channel 128 is a swept right angle or a curved shape and has a circular cross-section with a constant radius. However, other configurations may have different radii. Although the arc-shaped portion 126 is shown as a swept right angle, the arc-shaped portion 126 may have a sweep angle greater than 0 degrees and less than or equal to 90 degrees, consistent with the angle of the connector 110.
[0037] Receiving recess 129 ( Figure 9 The receiving recess 129 is disposed in the cable receiving section 122, near the cable receiving surface 124. The dimensions of the receiving recess 129 are adapted to receive the mating portion 131 of the second metal shell 113. The second metal shell 113 is configured to mate with and properly position the cable 111 so as to mate with the first metal shell 112.
[0038] like Figure 9 and 10As shown, the dielectric insert 114 can be formed by various methods, including molding or additive processes such as 3D printing. The dielectric insert 114 is made of an insulating material that is a poor electrical conductor. The dielectric insert 114 is configured to be positioned within a dielectric receiving channel 128. The dielectric insert 114 has a swept right-angle or curved shape and a circular cross-section with a constant radius extending from a first surface 130 near the mating connector receiving portion 118 to a second surface 132 near the substrate mounting portion 122. However, other configurations may have radii of different sizes. The first surface 130 extends in a plane substantially perpendicular to the plane extending from the second surface 132. The radius of the dielectric insert 114 is approximately equal to the radius of the dielectric receiving channel 128. The dielectric insert 114 has a contact receiving channel 134 extending through the dielectric insert 114 from the first surface 130 to the second surface 132. Although the dielectric insert 114 is shown as a swept right angle, the dielectric insert 114 may have a sweep angle greater than 0 degrees and less than or equal to 90 degrees, consistent with the angle of the connector 10.
[0039] The center contact 116 is made of conductive material and is located in the contact receiving channel 134. The center contact 116 is shaped as a swept right angle or curved and has a circular cross-section with a constant radius. However, other configurations may have radii of different sizes. The radius of the center contact 116 is approximately equal to the radius of the contact receiving channel 134. The center contact 116 has a first straight portion 136 extending into the mating connector receiving portion 18, a second straight portion 138 extending from the substrate cable receiving portion 122, and an arcuate portion 140 located in the contact receiving channel 134 and extending between the first straight portion 136 and the second straight portion 138. Although the arcuate portion 140 is shown as a swept right angle, the arcuate portion 140 may have a sweep angle greater than 0 degrees and less than or equal to 90 degrees, consistent with the angle of the connector 10.
[0040] Referring again to dielectric insert 114, dielectric insert 114 can be easily modified to minimize the effects of stray capacitance and improve impedance. In various embodiments, dielectric insert 114 can be adjusted by using a material with a higher or lower dielectric constant. Alternatively, the structure of dielectric insert 114 can be modified.
[0041] The dielectric insert 114 is made of two parts. In other embodiments, the dielectric insert 114 may have different constructions, such as, but not limited to, a single 3D-printed part.
[0042] like Figure 10 As shown, the first component 142 is a solid member, as... Figure 10As seen, it is located above the center contact 116. The first component 142 extends approximately 180 degrees around the center contact 116.
[0043] like Figure 10 As seen, the second component 144 is located below the center contact 116. The second component 144 extends approximately 180 degrees around the center contact 116. The second component 144 has a cavity 146 disposed therein. In the illustrative embodiment shown, the cavity 146 is a channel or conduit extending through the second component 144, but other configurations may also be used.
[0044] By introducing cavitation 16 to modify the dielectric insert 114, the effective dielectric constant of the dielectric insert 114 becomes a value between the dielectric constants of air and the dielectric material. The dielectric constant can be easily adjusted by changing the ratio of the dielectric material to air, or in other words, by increasing or decreasing the cavitation volume. Furthermore, the dielectric insert 114 can be locally fine-tuned, meaning the cavitation volume is controlled from one location to another within the dielectric insert 114, thus the effective dielectric constant of the dielectric insert 114 is different at different locations to match impedance matching requirements and end with smooth signal transmission. While the illustrative embodiment shows tubular cavitation 146, the second component 144 and the dielectric insert 114 can have other configurations and positioning of the cavitation.
[0045] The dielectric strength of the first component 142 and the second component 144 can be the same or can be varied to provide the desired performance. Furthermore, the sweep angle or curved shape of the connector 110, the gap between the center pin or contact 116 and the metal shell 112 is constant along the entire length of the arcuate portion 126 of the shell 112, thereby controlling its impedance and making it constant throughout its length, allowing the connector 110 to be used at very high frequencies. Since both the shell 112 and the center contact 16 are formed as a single piece, the risk of connector 10 failing due to shock or vibration is reduced compared to known connectors.
[0046] In the illustrated embodiment, connector 110 maintains signal integrity while altering the signal path by 90 degrees with a small bending radius. Figure 12 As shown, for signal frequencies up to at least 65 GHz, exemplary connector 110 has a voltage standing wave ratio (VSWR) of less than 1.2, as indicated by curve 150. This allows connector 110 to be used in applications requiring high precision and high density.
Claims
1. A swept-angle RF connector, comprising: A 3D-printed conductive shell, which is formed as a single piece and has a mating connector receiving portion with a mating connector receiving surface and a mounting portion with a mounting surface, the mating connector receiving surface extending in a plane substantially perpendicular to the plane extending from the mounting surface. An arc-shaped portion extending between the mating connector receiving portion and the mounting portion, a dielectric receiving channel disposed in the arc-shaped portion, the dielectric receiving channel being angular in shape and having a circular cross-section; A dielectric insert positioned in a dielectric receiving channel, the dielectric insert being of a swept-angle shape and having a circular cross-section extending from a first surface near the receiving portion of the mating connector to a second surface near the mounting portion, the first surface extending in a plane substantially perpendicular to the extension of the second surface, the contact receiving channel extending from the first surface through the dielectric insert to the second surface; The center contact is located in the contact receiving channel. The center contact is angular and has a circular cross-section.
2. The swoop angle RF connector as claimed in claim 1, wherein the dielectric receiving channel extends from the mating connector receiving portion to the substrate mating portion.
3. The swept-angle RF connector of claim 1, wherein the radius of the dielectric insert is approximately equal to the radius of the insulated receiving channel.
4. The swept-angle RF connector as claimed in claim 3, wherein the radius of the center contact is approximately equal to the radius of the contact receiving channel.
5. The swept-angle RF connector of claim 4, wherein the center contact has a first straight portion extending into the mating connector receiving portion, a second straight portion extending into the mounting portion, and an arcuate portion located in the contact receiving channel and extending between the first straight portion and the second straight portion.
6. The swept-angle RF connector of claim 1, wherein the dielectric insert comprises three components.
7. The sweep angle RF connector of claim 6, wherein one of the three components is a solid member extending approximately 180 degrees around the center contact.
8. The sweep angle RF connector of claim 6, wherein one of the three components is a component extending approximately 180 degrees around the center contact 16, the component having a cavity disposed therein.
9. The swept-angle RF connector of claim 8, wherein the cavitation is a channel or conduit extending through the second component.
10. The sweep angle RF connector of claim 6, wherein one of the three components extends 360 degrees around the center contact.
11. The swoop angle RF connector of claim 6, wherein the dielectric strength of the three components is substantially the same.
12. The swoop angle RF connector of claim 6, wherein the dielectric strengths of the three components are different.
13. The sweep angle RF connector of claim 1, wherein the connector is an ultra-miniature push-type miniature RF connector that maintains signal integrity while changing the signal path by 90 degrees with a small bending radius.
14. The swept-angle RF connector of claim 13, wherein the connector has a voltage standing wave ratio of less than 1.2 for signal frequencies up to 65 GHz.
15. The swept-angle RF connector of claim 1, wherein the second conductive shell extends from the 3D printed conductive shell.