Angled Coaxial Connector Inner Conductor Transition

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Solution Overview

Problem

Right angle coaxial connectors face challenges in assembly complexity due to the transition of the inner conductor, impedance discontinuity, and cost-effective precision manufacture, particularly with fragile and small-sized inner conductor elements.

Innovation Solution

A unitary, generally cylindrical inner conductor with a planar back angle surface transition and a spring basket interface connection, combined with Metal Injection Molding (MIM) or Thixoforming for precision and cost-effective manufacturing, reduces impedance discontinuity and assembly complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a right angle transition of the inner conductor is used to form a right angle coaxial connector, then the cable connection can be made normal to the device, but the assembly complexity increases due to difficulty in inserting the inner conductor and need for multiple pieces or access covers

Engineering Contradiction:

Improvecable connection orientationVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The inner conductor features a curved transition section with a specific radius of curvature that allows it to bend smoothly from the first longitudinal axis to the second longitudinal axis at right angles. This curved geometry enables the inner conductor to navigate the angle transition without requiring complex assembly procedures, access covers, or multiple pieces, thereby maintaining assembly simplicity while achieving the desired cable connection orientation.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If a right angle transition of the inner conductor is used, then the connector can connect to devices with space constraints, but impedance discontinuity is introduced into the coaxial transmission line

Engineering Contradiction:

Improvespace constraint accommodationVSAvoidimpedance continuity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The transition section of the inner conductor is designed with a carefully selected radius of curvature that balances two requirements: it must be tight enough to fit within space-constrained device housings, yet gentle enough to minimize impedance discontinuity. The curved geometry distributes the angular transition over a gradual arc, reducing abrupt impedance changes compared to sharp corner bends, thereby maintaining signal integrity while accommodating spatial limitations.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If the inner conductor element is made small in size for specific connection interfaces, then the connector can mate with various coaxial cable diameters, but the inner conductor becomes fragile and manufacturing precision becomes significantly more complicated

Engineering Contradiction:

Improveconnection interface compatibilityVSAvoidinner conductor fabrication precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The inner conductor is designed as a unitary, monolithic element formed from a single piece of conductive material, integrating the entire length including the transition section without joints or connections. This unitary construction eliminates weak points at transition zones, enhances mechanical strength despite the small size, and simplifies manufacturing by allowing the entire component to be produced in one operation, thereby achieving both connection interface compatibility and manufacturing feasibility.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances electrical performance by minimizing impedance discontinuity and intermodulation distortion while simplifying assembly and reducing manufacturing costs, achieving reliable installation with improved connector strength and precision.

Implementation Method 1

Metal Injection Molding (MIM) or Thixoforming for precision and cost-effective manufacturing

Methodology Applied

Scientific EffectMetal Injection Molding:

Implementation Method 2

Metal Injection Molding (MIM) or Thixoforming for precision and cost-effective manufacturing

Methodology Applied

Scientific EffectThixoforming:

Data Source

PatentUS7419403B1Angled coaxial connector with inner conductor transition and method of manufacture

Publication Date: 2008.09.02 OUTDOOR WIRELESS NETWORKS LLC

AI summary

An angled coaxial cable connector, having a unitary generally cylindrical inner conductor coaxial within a bore extending between a primary side and a secondary side of an outer body. The inner conductor provided with a first end on a primary longitudinal axis having a transition to a second end on a secondary axis at an angle to the primary longitudinal axis. An outer side of the transition having a planar back angle surface, the planar back angle surface arranged at generally one half of the angle to the longitudinal axis and to the secondary axis, respectively.