PCB Through Connector With Stepped Beam Lead for Wideband RF Transfer
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Solution Overview
Problem
In two-sided printed circuit boards (PCBs), efficient RF power transfer at high frequencies is hindered by reflections and unwanted leakage due to bandwidth limitations and complex quasi-coaxial structures, which require controlled impedance and containment within transmission lines.
Innovation Solution
A through connector device with a coaxial cable receiver portion, beam lead, and planar transmission line contact pad, featuring a step to create a gap between the beam lead and outer conductor, allowing impedance tuning and electrical contact with planar transmission lines, coupled via soldering, to interconnect RF signals across multi-layered PCBs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex quasi-coaxial structures are used for RF power transfer, then controlled impedance can be achieved, but device complexity increases and bandwidth is limited
Solution Approach 1:
The connector is divided into distinct functional segments: a coaxial cable receiver portion for receiving the coaxial cable, a beam lead portion with a step that creates a gap between the beam lead and outer conductor, and a planar transmission line contact pad. This segmentation allows each part to perform its specific function optimally while simplifying the overall structure compared to traditional quasi-coaxial designs.
Solution Approach 2:
The invention transitions from a traditional side-by-side quasi-coaxial structure to a vertical/dimensional arrangement where the beam lead extends upward from the contact pad and positions the center conductor above the outer conductor by a controlled gap distance. This dimensional change enables wideband impedance control without requiring complex interlayer metal patterns.
2Reliability
If traditional through connectors are used, then RF power can be transferred between PCB sides, but unwanted leakage and reflections occur due to bandwidth limitations
Solution Approach 1:
The beam lead includes a step that creates a specific gap distance between the beam lead bottom surface and the outer conductor top surface. This parameter change in the gap distance allows control of the electromagnetic field distribution, enabling wideband impedance control and reducing reflections and leakage across a broader frequency range compared to traditional connectors.
Solution Approach 2:
The beam lead acts as an intermediary element that bridges the coaxial cable receiver portion and the planar transmission line contact pad. The step in the beam lead creates a controlled gap that mediates the electromagnetic transition between the coaxial and planar transmission line structures, reducing impedance discontinuities and minimizing reflections.
3Reliability
If gap between beam lead and outer conductor is reduced for better coupling, then electrical contact improves, but electromagnetic interference increases
Solution Approach 1:
The step in the beam lead creates a controlled gap distance that is optimized to balance electrical coupling and electromagnetic interference. The gap is small enough to maintain good electrical contact and signal transfer but large enough to prevent excessive electromagnetic coupling between the beam lead and outer conductor, thereby reducing interference while maintaining reliability.
Data Source
AI summary
A through connector device is disclosed. The device may include a coaxial cable receiver portion defined by one or more surfaces, the coaxial cable receiver portion configured to couple to a center conductor portion of a coaxial cable, the center conductor portion of the coaxial cable protruding above a dielectric material of the coaxial cable. The device may include a beam lead positioned adjacent to the coaxial cable receiver portion. The device may include a planar transmission line contact pad configured to make electrical contact with a planar transmission line of a printed circuit board. The device may include a step configured to electrically and mechanically couple the beam lead to the planar transmission line contact pad, the step configured to create a gap between a bottom surface of the beam lead and a top surface of an outer conductor portion of the coaxial cable.