High Voltage RF Coaxial Connector Air Gap Design

The patent applies curvature by replacing sharp edges with rounded surfaces. Specifically, the connector features rounded edges and curved surfaces throughout its structure, including the dielectric insert and metal housing. This eliminates field concentration points where electrical breakdown would initiate, allowing the connector to withstand high voltages up to 215 kV without arcing or breakdown.

The patent changes physical parameters of the connector design, specifically the dielectric strength parameter and air gap dimensions. The air gap between conductive elements is precisely controlled at approximately 0.375 inches, and the dielectric material properties are selected to provide sufficient breakdown voltage margin. These parameter changes enable the connector to operate reliably at 215 kV peak voltage.

The patent merges multiple functions into integrated components. The dielectric insert simultaneously provides electrical insulation, mechanical support for the center conductor, and impedance control through its dimensional parameters. The metal housing combines shielding, structural support, and sealing functions. This integration reduces the number of separate parts while achieving the required dielectric strength and impedance matching.

The connector components are designed to perform multiple functions. The air gap serves both as a dielectric barrier preventing breakdown and as an impedance-matching element. The circular grooves in the dielectric insert provide both mechanical retention for conductors and electrical insulation. This multi-functionality reduces overall complexity despite the presence of multiple components.

The patent incorporates preliminary action by including molded-in features during the manufacturing process. The circular grooves, flanges, and positioning elements are formed directly during injection molding of the dielectric insert, ensuring consistent dimensions and tolerances. This preliminary formation of critical features eliminates subsequent machining operations that would introduce variability, maintaining the required 0.375-inch air gap tolerance across production batches.

The patent specifies precise parameter values that balance high voltage performance with manufacturability. The air gap is set at 0.375 inches (3/8 inch), which provides sufficient dielectric strength for 215 kV operation while being achievable with standard molding tolerances. The dielectric material thickness, conductor diameters, and groove dimensions are all optimized to this target gap, enabling mass production with consistent electrical performance.

The patent uses preliminary action by forming the air gap-defining features directly during injection molding. The dielectric insert's outer diameter, which determines the air gap dimension, is established in the molding process itself with tight process control. This eliminates subsequent machining or assembly steps that could introduce variability, ensuring consistent 0.375-inch air gaps that maintain 50-ohm impedance matching across all produced connectors.

The patent optimizes the air gap parameter to 0.375 inches, which provides a practical balance between impedance matching performance and manufacturing capability. This specific dimension achieves the required 50-ohm characteristic impedance for maximum power transfer while remaining within the capabilities of standard injection molding processes, ensuring consistent production without requiring ultra-precise tolerances that would increase cost and complexity.