Coaxial RF Connector Solid Insulation and Guiding Structure
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Solution Overview
Problem
Existing coaxial RF connection systems face issues with unstable electrical and mechanical performance over time, high passive intermodulation, and risk of connector damage due to lack of insulation and poor coaxiality, leading to signal distortion and reduced lifespan.
Innovation Solution
Incorporation of a solid insulating structure between the central and ground contacts, along with a longer guiding portion and optimized radial clearance, ensures mechanical protection and stable coaxiality, reducing passive and dynamic intermodulation levels while maintaining high RF performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a strong screwing torque is applied to the locking nut to ensure strong axial abutment contact between ground contacts, then passive intermodulation is minimized, but the connector dimensions become large and the torque requirement becomes excessive (30-35 N.m)
Solution Approach 1:
The connector is divided into separate functional components: a locking mechanism for mechanical engagement and a guiding portion for alignment. This segmentation allows the locking nut to focus solely on providing secure electrical contact without requiring excessive torque, while the guiding portion handles alignment independently.
Solution Approach 2:
The guiding portion with length L/D ≥ 0.5 performs preliminary alignment of the plug and jack before the locking nut is tightened. This preliminary action ensures proper coaxiality is established beforehand, allowing the locking mechanism to apply only the necessary torque for electrical contact rather than needing to overcome misalignment forces.
2Reliability
If the axial operating play (axial gap) is reduced to improve electrical contact, then ground connection stability improves, but the risk of damage to elastic ground contact increases without solid insulation protection
Solution Approach 1:
A solid insulating structure is introduced as an intermediary element between the central contact and ground contact. This insulator provides mechanical protection to the elastic ground contact during mating operations, allowing the connector to maintain stable electrical contact without risking damage to the elastic components.
Solution Approach 2:
The connector combines different materials with complementary properties: elastic material for the ground contact (providing compliance and stable contact pressure) and solid insulating material (providing mechanical protection and structural support). This composite approach allows the elastic contact to maintain stability while being protected from damage.
3Manufacturing precision
If the guiding portion length is increased to improve coaxiality and reduce tilting angle, then connection stability improves, but the connector length increases
Solution Approach 1:
The design optimizes the ratio L/D of the guiding portion length to diameter, specifying L/D ≥ 0.5. This parameter change achieves the desired coaxiality and tilting angle control (α ≤ 7°) while controlling the absolute length increase, balancing precision requirements with compact dimensions.
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 provides a stable and long-lasting coaxial connection with low passive and dynamic intermodulation, ensuring consistent RF performance and protecting the connectors from damage, while minimizing size and maintaining high RF signal transmission efficiency.
Implementation Method 1
each of the plug and the jack comprises a solid insulating structure interposed between the central contact and the ground contact
Implementation Method 2
the free end of the body is in longitudinal mechanical abutment against a part of the plug when they are in mutual connection configuration
Implementation Method 3
The electrical ground connection between ground contacts 21, 31 is thus produced only by the radial bearing of the elastic ground contact 31 against the interior of the recess of the rigid ground contact 21
Data Source
Figure 1
Figure 2~2A
Figure 3~3B
AI summary
The invention relates to a coaxial connection system in which solid insulating structures are used and it is provided a lengthening of the guide portion of the connectors, while ensuring an axial immobilization of the ground contacts independently of the locking device that mechanically locks the plug to the jack when they are in mutual connection configuration.