PIM Block for Coaxial Cable Soldered Connector
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coaxial cable and connector interconnections face issues with impedance discontinuity and signal degradation due to insulating discs, misalignment, and air/gas pockets, which lead to Passive Intermodulation Distortion (PIM) and reduced electro-mechanical characteristics.
Innovation Solution
A PIM block with an annular seat and cylindrical flange is used to align and solder the coaxial cable's outer conductor within the connector's solder bore, eliminating the need for an insulating disc and minimizing impedance discontinuity, while self-alignment features like tapers and slots ensure precise alignment and prevent air/gas pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an insulating disc is used to retain the connector against the cable, then the connector can be attached with quality control, but the insulating disc causes impedance discontinuity and can lead to PIM generation
Solution Approach 1:
The patent removes the insulating disc from the connector assembly, eliminating the source of impedance discontinuity and PIM generation while maintaining attachment quality through alternative means (direct contact between connector and cable components)
Solution Approach 2:
The patent applies selective plating (e.g., silver or gold plating) to specific surfaces of the connector and cable components to ensure proper soldering and electrical contact without requiring a full insulating disc, thereby maintaining local electrical quality while eliminating harmful impedance effects
2Ease of manufacture
If traditional soldering methods are used without alignment features, then the assembly process is simpler, but misalignment occurs leading to poor electro-mechanical characteristics
Solution Approach 1:
The patent incorporates pre-formed alignment features (such as tapered surfaces, slots, or positioning protrusions) on the connector or cable components that automatically guide proper alignment during assembly, ensuring accurate positioning before soldering occurs without complicating the overall assembly process
Solution Approach 2:
The patent introduces alignment features as intermediary geometric elements between the connector and cable components that facilitate proper positioning and registration, acting as a mediator that ensures accurate alignment while maintaining ease of assembly
3Productivity
If the outer conductor is not properly contained during soldering, then the assembly process is faster, but air/gas pockets form causing PIM and solder defects
Solution Approach 1:
The patent pre-configures the connector and cable components with containment features (such as recesses, clips, or positioning structures) that automatically hold the outer conductor in the correct position before soldering begins, preventing air pocket formation and eliminating the need for complex containment procedures during assembly
Solution Approach 2:
The patent designs the connector-cable assembly to be self-aligning and self-containing through integrated geometric features, where the components themselves provide the necessary containment and positioning functions without requiring additional external tools or complex assembly steps
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 enhances the electro-mechanical characteristics of the interconnection by reducing PIM, maintaining voltage breakdown potential, and preventing residue pathways, thereby improving the overall electrical performance and reliability of RF systems.
Implementation Method 1
An outer diameter of the outer conductor is coupled to an inner diameter of the solder bore via a solder joint
Data Source
AI summary
A cable-connector assembly includes: a coaxial connector having an outer connector body with a solder bore; a coaxial cable having an inner conductor and an outer conductor, the outer conductor seated within the solder bore; and a PIM block comprising an annular seat and a generally cylindrical flange extending from an outer periphery of the annular seat along a longitudinal axis of the annular seat. A leading edge of the outer conductor of the cable is inserted within the flange of the PIM block. An outer diameter of the outer conductor is coupled to an inner diameter of the solder bore via a solder joint.