Compressible Connector Contacts for Low-Loss PCB Transitions
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Solution Overview
Problem
Existing connector assemblies for high-frequency applications suffer from signal loss and discontinuities due to right-angle transitions to printed circuit boards, particularly above 10 GHz, and lack solderless center contacts and housings that maintain low signal loss.
Innovation Solution
The development of connector assemblies featuring compressible electrical contacts with divaricating patterns, precision-cut to maintain a flexible tubular form and compensate for mating conductor tolerances, along with low-profile dielectrics and housings, which guide center conductors through angles up to 90 degrees, reducing signal loss and improving mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional right-angle transitions to PCB are used, then connector assembly is simplified, but signal loss increases above 10 GHz
Solution Approach 1:
The patent employs dynamic compression of the center conductor within a compressible contact structure, allowing the conductor to be compressed to a reduced diameter and rotated to align with the PCB trace. This dynamic adjustment eliminates the need for fixed right-angle transitions while maintaining manufacturing simplicity.
Solution Approach 2:
The invention changes the physical parameters of the center conductor by compressing it to a reduced diameter and rotating it to a different orientation. This parameter transformation allows the connector to achieve low signal loss at high frequencies while maintaining ease of assembly through a standardized interface.
2Loss of time
If solderless center contacts are used, then assembly time is reduced, but maintaining constant electrical connection at high frequencies becomes difficult
Solution Approach 1:
The compressible contact structure is pre-designed with compression capability to compensate for tolerance variations in the center conductor. This beforehand cushioning ensures that constant electrical connection is maintained at high frequencies without requiring soldering, thus reducing assembly time while preserving reliability.
3Manufacturing precision
If precision-cut compressible contacts with divaricating patterns are used, then tolerance compensation is improved, but manufacturing complexity increases
Solution Approach 1:
The center conductor is segmented into multiple sections through precision cutting with divaricating patterns. This segmentation allows each section to move independently, providing tolerance compensation while maintaining a relatively simple overall structure that does not excessively increase manufacturing complexity.
4Measurement precision
If center conductor is compressed to reduced diameter, then alignment with PCB trace is improved, but contact pressure requirements increase
Solution Approach 1:
The dynamic compression mechanism allows the center conductor to be compressed to a reduced diameter for improved alignment with the PCB trace. The compressible contact structure is designed to distribute the contact pressure, managing the increased force requirements while achieving the alignment precision needed for high-frequency performance.
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
These assemblies achieve low insertion and return losses up to 65 GHz, maintaining constant electrical and mechanical connections while simplifying transitions between PCBs and reducing discontinuities.
Implementation Method 1
Each compressible electrical contact is configured to vary its length, compensate for tolerance ranges/deviations of mating center conductors or cables, and maintain constant electrical/mechanical connection upon assembly
Data Source
AI summary
Various configurations of connector assemblies are disclosed herein. Each variation of connector assembly includes at least one conductive outer housing, one or more dielectrics, and conductors, some of which may be configured as compressible electrical contacts manufactured from a tube. One embodiment of the compressible electrical contact includes a first contact end, a second contact end opposing the first contact end, and a plurality of cut sections defined by at least one cut angle measured between a pair of outwardly extending opposing inner surfaces, an innermost cut distance, and an outermost cut distance. Each of the plurality of divaricated-cut sections is based on at least one divaricating pattern.