Split insulator systems and methods for radio frequency connectors

Abstract

A connector is provided. The connector includes a contact configured to engage a center conductor of a coaxial line. The contact includes a contact body extending along an axis and an annular shoulder extending radially from the contact body. The connector further includes a first insulating disk and a second insulating disk coaxial with the contact body. The annular shoulder is disposed between and in contact with the first insulating disk and the second insulating disk. The connector further includes a connector body coaxial with the contact body and defining an annular groove that receives the first insulating disk and the second insulating disk. The first insulating disk and the second insulating disk retain the contact in position with respect to the connector body.

Description

SPLIT INSULATOR SYSTEMS AND METHODS FOR RADIO FREQUENCY CONNECTORSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to U.S. Provisional Patent Application No. 63 / 602,847, filed 27 November 2023. which is incorporated herein by reference in its entirety.BACKGROUND

[0002] The embodiments described herein relate generally to electrical interconnects and, more particularly, to radio frequency (RF) coaxial connectors.

[0003] Coaxial connectors are used as output connections on module designs. Generally, coaxial connectors that accommodate higher frequency signals (e.g., w-band signals) while maintaining signal integrity and a compact package size are considered useful, particularly when intended for use in rugged environments, such as space and military applications. Further, when used in such environments, it is beneficial for these coaxial connectors to mate securely without becoming disconnected due to mechanical shock, vibrations, or other forces. An improved coaxial connector is therefore desirable.BRIEF SUMMARY

[0004] In one aspect, a connector is provided. The connector includes a contact configured to engage a center conductor of a coaxial line. The contact includes a contact body extending along an axis and an annular shoulder extending radially from the contact body. The connector further includes a first insulating disk and a second insulating disk coaxial with the contact body. The annular shoulder is disposed between and in contact with the first insulating disk and the second insulating disk. The connector further includes a connector body coaxial with the contact body and defining an annular groove that receives the first insulating disk and the second insulating disk. The first insulating disk and the second insulating disk retain the contact in position with respect to the connector body.

[0005] In another aspect, a method for manufacturing a connector is provided. The method includes forming a contact configured to engage a center conductor of a coaxial line. The contact includes a contact body extending along an axis and an annular shoulder extending radially from the contact body. The method further includes positioning a first insulating disk and a second insulating disk coaxially with the contact body. The annular shoulder is disposed between and in contact with the first insulating disk and the second insulating disk. The method further includes positioning a connector body coaxially with the contact body. The connector body defines an annular groove that receives the first insulating disk and the second insulating disk. The first insulating disk and the second insulating disk retain the contact in position with respect to the connector body.

[0006] In another aspect, a connector system is provided. The connector system includes a first connector including a contact configured to engage a center conductor of a coaxial line. The contact includes a contact body extending along an axis and an annular shoulder extending radially from the contact body. The first connector further includes a first insulating disk and a second insulating disk coaxial with the contact body. The annular shoulder is disposed between and in contact with the first insulating disk and the second insulating disk. The first connector further includes a connector body coaxial with the contact body and defining an annular groove that receives the first insulating disk and the second insulating disk. The first insulating disk and the second insulating disk retain the contact in position with respect to the connector body. The connector system further includes a second connector configured to engage the first connector such that the contact of the first connector electrically couples to a second contact of the second connector.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIGS. 1-15 show example embodiments of the systems and methods described herein.

[0008] FIG. 1 is a perspective view of an example female connector;

[0009] FIG. 2 is a perspective cross-sectional view of the example female connector shown in FIG. 1 ;

[0010] FIG. 3 is another cross-sectional view of the example female connector shown in FIGS. 1-2;

[0011] FIG. 4 is a perspective view of an example contact for use in the example female connector shown in FIGS. 1-3;

[0012] FIG. 5 is a perspective view of an example insulating disk for use in the example female connector shown in FIGS. 1-3;

[0013] FIG. 6 is a perspective view of an example male connector;

[0014] FIG. 7 is a perspective cross-sectional view of the example male connector shown in FIG. 6;

[0015] FIG. 8 is a perspective view of an example contact for use in the example male connector shown in FIGS. 6 and 7;

[0016] FIG. 9A is a cross-sectional view' of a connector assembly including the example female connector shown in FIGS. 1-3 and the example male connector shown in FIGS. 6 and 7 in an unlocked state;

[0017] FIG. 9B is a cross-sectional view' of the connector assembly shown in FIG. 9A in a locked state:

[0018] FIG. 10 is a perspective view of the connector assembly shown in FIGS. 9 A and 9B;

[0019] FIG 11 is a graph illustrating electrical (RF) properties of the female connector shown in FIGS. 1-3;

[0020] FIG 12 is another graph illustrating electrical (RF) properties of the female connector shown in FIGS. 1-3;

[0021] FIG 13 is another graph illustrating electrical (RF) properties of the female connector shown in FIGS. 1-3;

[0022] FIG 14 is another graph illustrating electrical (RF) properties of the female connector shown in FIGS. 1-3;

[0023] FIG. 15 is a flow chart illustrating an example method for manufacturing a connector such as the connector shown in FIGS. 1-3.DETAILED DESCRIPTION

[0024] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0025] The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

[0026] Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary' without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately.” and “substantially,” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations are combined and interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0027] The embodiments described herein include a connector. In example embodiments, the connector includes a contact configured to engage a center conductor of a coaxial line. The contact includes a contact body extending along an axis and an annular shoulder extending radially from the contact body. In some embodiments, the annular shoulder is positioned at or near a lengthwise center of the contact body. A size and position of the annular shoulder is selected to reduce or eliminate signal degradation due to resonance or other electromagnetic effects. The connector further includes a first insulating disk and a second insulating disk positionedcoaxially with the contact body. The annular shoulder is positioned between and in contact with the first and second insulating disks, such that the first and second insulating disks, when held together, may hold the contact in a fixed position. As with the annular shoulder, a size and shape of the insulating disks is selected to reduce or eliminate signal degradation due to resonance or other electromagnetic effects. For example, in some embodiments, the insulating disks include one or more through holes to enable a reduction of dielectric constant material property, thereby improving RF performance by reducing resonance and signal loss at radio frequencies.

[0028] The connector further includes a connector body positioned coaxially with the contact body and defining an annular groove configured to receive the first insulating disk and the second insulating disk. Because the first and second insulating disks are held together by the connector body, the first and second insulating disks retain the contact in a precise and mechanically sound coaxial position with respect to the connector body. By captivating the contact at a single point at or near its center, a relatively thin contact may be used, which may enable higher frequency signals to be transmitted through the connector. For example, in some embodiments, signals of up to 110 gigahertz can be transmitted through the connector without significant degradation. In some cases, captivating the contact at a single point from at or near its center may enable transmission of higher frequency signals than would be enabled by using other forms of captivation, such as by supporting the contact from each side, or by using a single insulator with other methods of captivation such as a knurl or barb on the contact. Accordingly, using a split (i.e., two-disk) insulator solves two problems: (a) mechanical (captivation of the contact) and (b) electrical (high frequency RF performance).

[0029] In some embodiments, the connectors described herein can be one of either a female connector or a male connector, with a female connector and male connector being capable of coupling and locking to one another. For example, in some embodiments, the connector body of the female connector may include a locking sleeve and one or more locking members. The locking sleeve can be moved (e.g., back and forth along an axis of the connector) from an unlocked to a locked position, such thatwhen the locking sleeve is in the locked position, the locking members are pushed so that the locking members engage (e.g., catch) a locking groove of the male connector.

[0030] FIG. 1 is a perspective view of an example female connector 100. FIGS. 2 and 3 are cross-sectional views of female connector 100. Female connector 100 includes a contact 102 and a connector body 104, which are configured to be electrically coupled to a center conductor and a shield or outer conductor of a coaxial transmission line (e.g.,, a coaxial cable). Connector body 104 includes a locking sleeve 106 and one or more locking members 108, which are described in further detail below with respect to FIGS. 9 and 10. Contact 102 and connector body 104 are positioned coaxially about an axis 110.

[0031] Referring to FIGS. 2 and 3, female connector 100 further includes one or more insulating disks 202 configured to retain contact 102 in position with respect to connector body 104. Contact 102 includes an elongate contact body 204 and an annular shoulder 206 extending radially from contact body 204. Insulating disks 202 are positioned adjacently and retained by an annular groove 208 of connector body 104. Contact 102 extends through respective center holes 210 of insulating disks 202, such that annular shoulder 206 is secured between insulating disks 202, thereby supporting contact 102 in place with respect to connector body 104. In some embodiments, as shown in FIGS. 2 and 3, annular shoulder 206 is positioned at or substantially near a lengthwise center of contact body 204 (i.e., a middle position along axis 110), so that contact is supported by insulating disks 202 at its center. Because contact 102 is supported from its center, contact 102 can be relatively small in diameter (e.g., about 0.024 inches), which enables contact 102 to carry relatively high frequency signals (e.g., up to 110 gigahertz).

[0032] FIG. 4 is a perspective view of contact 102. Contact 102 is configured to engage with and electrically couple to a contact of a male connector (such as contact 602 of male connector 600, described below with respect to FIGS. 6-8). In some embodiments, contact 102 may be relatively narrow, which enables contact 102 to carry relatively high frequency signals (e.g., up to 110 gigahertz).

[0033] FIG. 5 is a perspective view of an example embodiment of insulating disk 202. Insulating disk 202 defines a center hole 210. through which contact 102 may pass, and one or more outer holes 502. The specific size, shape, and location of outer holes 502 may be selected such that outer holes 502 reduce or eliminate electromagnetic resonance and signal loss. FIG. 5 illustrates one such example arrangement of outer holes 502, and it should be appreciated that other arrangements of outer holes 502 may also reduce or eliminate electromagnetic resonance within an operating band of female connector 100 (e.g., up to 110 gigahertz) to maintain a consistent characteristic impedance (e.g., 50 ohms). In some embodiments, insulating disk 202 is made from Rexolite or another insulating material with a relatively low dielectric constant (e.g., less than 2.5).

[0034] As shown in FIG. 5, insulating disk 202 further defines a counterbore 504. Counterbore 504 is sized and shaped to receive annular shoulder 206. For example, in some embodiments, counterbore 504 has a diameter approximately equal to that of annular shoulder 206, and a depth of approximately half a thickness of annular shoulder 206. Annular shoulder 206 can therefore be securely held in place when positioned within respective counterbores 504 of two adjacent insulating disks 202.

[0035] FIG. 6 is a perspective view of an example male connector 600, which is configured to mate with female connector 100 (shown in FIGS. 1-3), as described in further detail below with respect to FIGS. 9 and 10. FIG. 7 is a cross- sectional view of male connector 600. In some embodiments, male connector 600 is configured to be mounted on a panel or other surface. Male connector 600 includes a contact 602, insulating disks 604, and connector body 606, which are positioned coaxially about an axis 608. Contact 602 functions similarly to contact 102 of female connector 100, and insulating disks 604 function similarly to insulating disks 202 of female connector 100. Connector body 606 includes a locking groove 610, which is described in further detail below with respect to FIGS. 9 and 10. As shown in FIG. 7, contact 602 includes a contact body 702 and an annular shoulder 704, which function similarly to contact body 204 and annular shoulder 206, respectively , and connector body 606 also includes an annular groove 706, which functions similarly to annulargroove 208. While connector body 606 is illustrated in FIG. 6 as having a two-hole flange structure for mounting on a surface, in alternative embodiments, connector body 606 may include a different mounting structure. For example, connector body 606 may be configured to be mounted on a printed circuit board (PCB).

[0036] FIG. 8 is a perspective view of contact 602. Contact 602 is configured to engage with a contact with contact of a female connector (such as contact 102 of female connector 100 described above with respect to FIGS. 1-4). In some embodiments, contact 602 may be relatively small in diameter, which enables contact 102 to carry relatively high frequency signals (e.g., up to 110 gigahertz).

[0037] FIGS. 9A and 9B are cross-sectional views of an example connector system 900 including female connector 100 and male connector 600. FIG. 9A shows connector system 900 in an unlocked state, and FIG. 9B shows connector system in a locked state. FIG. 10 is a perspective view of connector system 900. Female connector 100 is configured to engage male connector 600 such that contact 102 of the female connector electrically couples to contact 602 of male connector 600. Locking sleeve 106 of connector body 104 is configured to slide from an unlocked position (as shown in FIG. 9A) to a locked position (as shown in FIG. 9B). Referring to FIGS. 9A and 9B, as locking sleeve 106 is slid along connector body 104 toward male connector 600, locking members 108 are pushed radially inw ard, as shown in FIG. 9B, such that locking members 108 engage (e.g., catch) locking groove 610 of connector body 606, thereby locking female connector 100 and male connector 600 together. As shown in FIG. 10. when locking sleeve 106 is in the locked position, a locking indicator 1002 (e.g., a colored band) of female connector 100 is revealed and exposed, enabling a person to visually confirm that female connector 100 and male connector 600 are locked. While locking indicator 1002 is illustrated as a band in FIG. 10, it should be appreciated that locking indicator 1002 may have any suitable shape and design to facilitate visually alerting a user that female connector 100 and male connector 600 are locked together.

[0038] FIG. 11 is a graph 1100 illustrating properties of a gated female connector 100 when tested with a frequency sweep from 10 megahertz to 70 gigahertz. Graph 1 100 includes a first plot 1102 showing a voltage standing wave ratio (VSWR)over the tested range and a second plot 1104 showing a characteristic impedance over the tested range. As shown in first plot 1102, a maximum VSWR over the tested range is about 1.24, and as shown by second plot 1104, the characteristic impedance deviates from the nominal 50 ohm characteristic impedance by a maximum of about 5 ohms.

[0039] FIG. 12 is a graph 1200 illustrating properties of another gated female connector 100 when tested with a frequency sw eep from 10 megahertz to 70 gigahertz. Graph 1200 includes a first plot 1202 showing a VSWR over the tested range and a second plot 1204 showing a characteristic impedance over the tested range. As shown in first plot 1202, a maximum VSWR over the tested range is about 1.25, and as shown by second plot 1204, the characteristic impedance deviates from the nominal 50 ohm characteristic impedance by a maximum of about 6.2 ohms.

[0040] FIG. 13 is a graph 1300 illustrating properties of a gated female connector 100 when tested with a frequency sweep from 11 megahertz to 110 gigahertz. Graph 1300 includes a first plot 1302 showing a VSWR over the tested range and a second plot 1304 showing a characteristic impedance over the tested range. As show n in first plot 1302, a maximum VSWR over the tested range is about 1.35, and as shown by second plot 1304, the characteristic impedance deviates from the nominal 50 ohm characteristic impedance by a maximum of about 6 ohms.

[0041] FIG. 14 is a graph 1400 illustrating properties of another gated female connector 100 when tested with a frequency sweep from 11 megahertz to 110 gigahertz. Graph 1400 includes a first plot 1402 showing a VSWR over the tested range and a second plot 1404 showing a characteristic impedance over the tested range. As shown in first plot 1402, a maximum VSWR over the tested range is about 1.45, and as shown by second plot 1404, the characteristic impedance deviates from the nominal 50 ohm characteristic impedance by a maximum of about 8 ohms.

[0042] FIG. 15 is a flowchart of an example method 1500 for manufacturing a connector such as female connector 100 or male connector 600.

[0043] In the example embodiment, method 1500 includes forming1502 a contact (such as contact 102 or contact 602) configured to engage a centerconductor of a coaxial line, the contact including a contact body (such as contact body 204 or contact body 702) extending along an axis (such as axis 110 or axis 608) and an annular shoulder (such as annular shoulder 206 or annular shoulder 704) extending radially from the contact body.

[0044] In the example embodiment, method 1500 further includes positioning 1504 a first insulating disk and a second insulating disk (such as insulating disks 202 or insulating disks 604) coaxially with the contact body, wherein the annular shoulder is disposed between and in contact with the first insulating disk and the second insulating disk.

[0045] In the example embodiment, method 1500 further includes positioning 1506 a connector body (such as connector body 104 or connector body 606) coaxially with the contact body. The connector body defines an annular groove (such as annular groove 208 or annular groove 706) configured to receive the first insulating disk and the second insulating disk, wherein the first insulating disk and the second insulating disk retain the contact in position with respect to the connector body.

[0046] In some embodiments, method 1500 further includes forming the annular shoulder at substantially a lengthwise center of the contact body.

[0047] In some embodiments, the first insulating disk and the second insulating disk include at least one hole (such as outer holes 502) extending therethrough substantially parallel to the axis of the contact body.

[0048] In some embodiments, the first insulating disk and the second insulating disk are configured to reduce electromagnetic resonance and / or signal loss at operating radio frequencies of the connector.

[0049] In some embodiments, the first insulating disk defines a first counterbore and the second insulating disk defines a second counterbore, and the contact is retained in position within the first counterbore and the second counterbore.

[0050] In some embodiments, the connector includes a female connector (such as female connector 100) configured to engage a male connector (such as male connector 600) such that the contact of the female connector (such as contact 102) electrically couples to a corresponding contact of the male connector (such as contact 602).

[0051] In some embodiments, the connector body includes a locking sleeve (such as locking sleeve 106) and one or more locking members (such as locking members 108), wherein when the locking sleeve is moved along the axis of the contact towards the male connector to a locked position, the locking sleeve causes the one or more locking members to engage a locking groove (such as locking groove 610) of the male connector to lock the connector body to the male connector.

[0052] In some embodiments, the connector body includes a locking indicator (such as locking indicator 1002), wherein the locking indicator is revealed and exposed when the locking sleeve is moved to the locked position.

[0053] Example embodiments of methods and systems for RF connectors are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and / or steps of the methods may be used independently and separately from other components and / or steps described herein. Accordingly, the example embodiments can be implemented and used in connection with many other applications not specifically described herein.

[0054] Technical effects of the systems and methods described herein include at least one of: (a) improving signal integrity at higher frequencies of a coaxial connector by supporting a contact of the coaxial connector at or near its center using an annular shoulder supported (or "sandwiched’7) between two insulating disks, which in turn are supported by a body of the contact: and (b) enabling a pair of coaxial connectors to be securely fastened by providing a female connector including a locking sleeve which, when moved into a locked position, causes one or more locking members of the female connector to grasp a locking groove of a male connector.

[0055] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0056] This written description uses examples to disclose various embodiments, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A connector comprising: a contact configured to engage a center conductor of a coaxial line, said contact comprising a contact body extending along an axis and an annular shoulder extending radially from said contact body; a first insulating disk and a second insulating disk coaxial with said contact body, wherein said annular shoulder is disposed between and in contact with said first insulating disk and said second insulating disk; and a connector body coaxial with said contact body and defining an annular groove that receives said first insulating disk and said second insulating disk, wherein said first insulating disk and said second insulating disk retain said contact in position with respect to said connector body.

2. The connector of Claim 1, wherein said annular shoulder is positioned substantially at a lengthwise center of said contact body.

3. The connector of Claim 1. wherein said first insulating disk and said second insulating disk include at least one hole extending therethrough substantially parallel to the axis of the contact body.

4. The connector of Claim 1. wherein said first insulating disk and said second insulating disk are configured to reduce electromagnetic resonance and / or signal loss at operating radio frequencies of said connector.

5. The connector of Claim 1. wherein said first insulating disk defines a first counterbore and said second insulating disk defines a second counterbore, and wherein said contact is retained in position within the first counterbore and the second counterbore.

6. The connector of Claim 1, wherein said connector comprises a female connector configured to engage a male connector such that said contact of said female connector electrically couples to a corresponding contact of said male connector.

7. The connector of Claim 6, wherein said connector body comprises a locking sleeve and one or more locking members, wherein when said locking sleeve is moved along the axis of the contact body towards said male connector to a locked position, said locking sleeve causes said one or more locking members to engage a locking groove of the male connector to lock said connector body to the male connector.

8. The connector of Claim 7, wherein said connector body comprises a locking indicator, wherein said locking indicator is configured to be exposed when said locking sleeve is moved to the locked position.

9. A method for manufacturing a connector, said method comprising: forming a contact configured to engage a center conductor of a coaxial line, the contact including a contact body extending along an axis and an annular shoulder extending radially from the contact body; and positioning a first insulating disk and a second insulating disk coaxially with the contact body, wherein the annular shoulder is disposed between and in contact with the first insulating disk and the second insulating disk; and positioning a connector body coaxially with the contact body, the connector body defining an annular groove that receives the first insulating disk and the second insulating disk, wherein the first insulating disk and the second insulating disk retain the contact in position with respect to the connector body.

10. The method of Claim 9, further comprising forming the annular shoulder substantially at a lengthwise center of the contact body.

11. The method of Claim 9, wherein the first insulating disk and the second insulating disk include at least one hole extending therethrough substantially parallel to the axis of the contact body.

12. The method of Claim 9, wherein the first insulating disk and the second insulating disk are configured to reduce electromagnetic resonance and / or signal loss at operating radio frequencies of said connector.

13. The method of Claim 9, wherein the connector comprises a female connector configured to engage a male connector such that the contact of the female connector electrically couples to a corresponding contact of the male connector.

14. The method of Claim 13, wherein the connector body includes a locking sleeve and one or more locking members, wherein when the locking sleeve is moved along the axis of the contact body towards the male connector to a locked position, the locking sleeve causes the one or more locking members to engage a locking groove of the male connector to lock the connector body to the male connector.

15. The method of Claim 14, wherein the connector body includes a locking indicator, wherein the locking indicator is exposed when the locking sleeve is moved to the locked position.

16. A connector system comprising: a first connector comprising: a contact configured to engage a center conductor of a coaxial line, said contact comprising a contact body extending along an axis and an annular shoulder extending radially from said contact body; and a first insulating disk and a second insulating disk coaxial with said contact body, wherein said annular shoulder is disposed between and in contact with said first insulating disk and said second insulating disk; and a connector body coaxial with said contact body and defining an annular groove that receives said first insulating disk and said second insulating disk, wherein said first insulating disk and said second insulating disk retain said contact in position with respect to said connector body; and a second connector configured to engage said first connector such that said contact of said first connector electrically couples to a second contact of said second connector.

17. The connector system of Claim 16, wherein said second connector compnses:a third insulating disk and a fourth insulating disk coaxial with a second contact body of the second contact, wherein a second annular shoulder of the second contact is disposed between and in contact with said third insulating disk and said fourth insulating disk; and a second connector body positioned coaxially with the second contact and defining a second annular groove that receives said third insulating disk and said fourth insulating disk, wherein said third insulating disk and the fourth insulating disk retain the second contact in position with respect to said second connector body.

18. The connector system of Claim 16, wherein said annular shoulder is positioned substantially at a lengthwise center of said contact body.

19. The connector system of Claim 16, wherein said first insulating disk and said second insulating disk include at least one hole extending therethrough substantially parallel to the axis of the contact body.

20. The connector system of Claim 16, wherein said first connector comprises a female connector and wherein said second connector comprises a male connector.

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