Coaxial Connector Interconnection Cap for Impedance and Sealing
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Solution Overview
Problem
Prior coaxial connectors face challenges with complex manufacturing and assembly due to multiple environmental seals, and require extensive redesign for impedance matching with new coaxial cable materials like aluminum, which can lead to corrosion and performance degradation.
Innovation Solution
A coaxial interconnection cap that provides local isolation of the interconnection area with reduced seal area, using a monolithic body with dimensioned bores and seal grooves to enhance environmental sealing and impedance matching, and can be easily integrated with existing connectors by replacing traditional insulators, with optional surface sealants to prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple environmental seals are used in prior coaxial connectors, then environmental sealing is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple seal functions into a single integrated seal structure. The seal member is configured to simultaneously seal against the inner conductor, outer conductor, and connector body, replacing what would traditionally require multiple separate seals. This merging reduces structural complexity while maintaining comprehensive environmental protection.
Solution Approach 2:
The seal member serves multiple functions simultaneously: it provides environmental sealing, supports the inner conductor, maintains positional alignment, and prevents moisture ingress. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity while improving reliability.
2Reliability
If coaxial connectors are tuned for impedance matching with specific cables, then electrical performance is improved, but manufacturing cost and inventory complexity increase due to multiple connector designs
Solution Approach 1:
The patent introduces adjustable impedance matching elements that can be configured after manufacturing. The connector includes mechanisms to adjust the electrical characteristics to match different cable types, allowing a single connector design to serve multiple impedance requirements rather than requiring separate fixed designs for each cable type.
Solution Approach 2:
The connector incorporates elements whose electrical parameters can be modified to achieve impedance matching with different coaxial cables. This may include adjustable dielectric elements or conductor positioning mechanisms that change electrical characteristics without requiring complete redesign of the connector for each cable type.
3Manufacturing precision
If coring tools are used to remove foam dielectric for impedance matching, then impedance matching is achieved, but manufacturing cost increases and precision is reduced
Solution Approach 1:
The connector is pre-configured with impedance matching elements during manufacturing, eliminating the need for field coring operations. The design incorporates features that automatically achieve proper impedance matching without requiring additional tools or precision removal operations after the connector is assembled.
4Ease of manufacture
If aluminum inner conductors are used in coaxial cables, then material cost is reduced, but corrosion and oxidation resistance deteriorates
Solution Approach 1:
The seal member and connector design create a protective barrier between the aluminum inner conductor and environmental factors. This intermediary sealing structure prevents moisture and air contact with the aluminum, eliminating corrosion issues while allowing the use of cost-effective aluminum material.
Data Source
AI summary
A coaxial connector is combined with an inner conductor interconnection cap, for interconnection with a coaxial cable. The interconnection cap is provided with a bore adapted to seat upon and circumferentially contact an outer diameter of the inner contact and an outer diameter of the inner conductor. The interconnection cap extends along the inner contact to cover at least a contact portion at a cable end of the inner contact to enclose an interconnection between the inner conductor and the inner contact. Sealant may be applied to the interconnection to improve seal performance and the dimensions and materials of the interconnection cap may be adjusted to modify characteristic impedance for return loss optimization with respect to specific coaxial cables.