Folded Surface Capacitor Inline Assembly for Coaxial Impedance Control
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Solution Overview
Problem
Prior inline capacitor assemblies for coaxial cables have limitations in power ratings, are fragile, expensive, and introduce impedance discontinuities due to conventional electronic components and structural issues, especially at high temperatures, and struggle to handle increased frequency bands and power requirements.
Innovation Solution
The inline capacitor assembly features a dielectric spacer with folded mating surfaces and a ceramic dielectric material, providing increased surface area and power handling capacity while minimizing impedance discontinuities and structural requirements, using a compact design with a ceramic dielectric spacer and a rotational interlock mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional electronic components (ceramic disc or SMD capacitors) are mounted within a shielding enclosure, then the capacitor assembly can be manufactured, but the power rating is limited and the assembly becomes fragile and expensive
Solution Approach 1:
The patent replaces expensive, fragile conventional electronic components (ceramic disc or SMD capacitors) with a simple, robust structure consisting of a conductive element, dielectric material, and housing that can withstand high power ratings without being fragile. This substitution of inexpensive, durable materials for expensive, fragile components directly resolves the contradiction between power rating and reliability.
2Reliability
If conventional electronic components are used in in-line capacitor assemblies, then the capacitor can block DC and low frequency signals, but significant impedance discontinuity is introduced to the coaxial line
Solution Approach 1:
The patent applies local quality by designing the conductive element and dielectric material configuration to specifically address the impedance discontinuity problem at the capacitor location while maintaining the signal blocking capability. The tapered shape of the conductive element and the specific dielectric material placement create a gradual transition that minimizes impedance discontinuity locally, while the overall structure maintains the necessary DC and low frequency signal blocking function.
3Ease of operation
If adhesives are used to mount capacitors on the center conductor, then the capacitor can be positioned, but the adhesive softens and shifts at high operating temperatures, permanently affecting capacitance
Solution Approach 1:
The patent extracts and eliminates the adhesive mounting system entirely. Instead of using adhesives to mount the capacitor on the center conductor, the design uses a self-supporting structure where the conductive element is mechanically supported by the housing and positioned relative to the outer conductor through the dielectric material and housing geometry. This removal of the temperature-sensitive adhesive component eliminates the problem of capacitance drift at high temperatures while maintaining ease of assembly through the simplified mechanical structure.
4Manufacturing precision
If a dielectric spacer is inserted between mating pin and socket ends to form a capacitor, then the desired capacitance value can be achieved, but significant supporting structure is required to maintain alignment
Solution Approach 1:
The patent merges the dielectric spacer function with the housing structure. The housing itself serves as the supporting structure that maintains alignment between the inner conductor segments, eliminating the need for separate, complex supporting structures. The dielectric material is integrated into the housing or positioned within it, combining the electrical insulation function with the mechanical support function, thereby achieving the desired capacitance value with minimal device complexity.
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
This design enhances power handling, capacitance, and reduces impedance discontinuities, assembly weight, and size, while maintaining precise gap distances and thermal stability, addressing the limitations of prior solutions.
Implementation Method 1
The capacitance resulting from these solutions is determined by the dielectric value of the spacer material, the gap distance and surface area of the mating surfaces
Implementation Method 2
maintaining precise gap distances and thermal stability, addressing the limitations of prior solutions
Data Source
AI summary
An in-line capacitor, having a pair of inner conductor segments, each of the inner conductor segments having a mating surface. A dielectric spacer positioned between the mating surfaces, each of the mating surfaces having corresponding folds formed thereon.