RF Connector Low PIM Monolithic Spring-Loaded Outer Conductor
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Solution Overview
Problem
Existing coaxial connectors in the RF spectral range face challenges in minimizing passive intermodulation (PIM) due to precision contact designs and high contacting forces, which can lead to increased mechanical tolerances and electrical connections with potential oxide layers.
Innovation Solution
A coaxial socket connector with a spring-loaded outer conductor featuring parallel slits forming spring-loaded contact elements, a monolithic base and outer housing configuration that eliminates electrical connections between parts, and precision centering means for precise alignment, ensuring even contact forces and reduced PIM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If precision contact design and high contacting forces are used, then passive intermodulation is reduced, but mechanical tolerances increase
Solution Approach 1:
The outer conductor is divided into multiple spring-loaded contact elements through parallel slits, transforming a single rigid contact surface into multiple independent elastic contacts. This segmentation allows each contact element to independently accommodate manufacturing tolerances while maintaining high contact pressure, thereby reducing PIM without requiring extremely tight mechanical tolerances across the entire connector interface.
Solution Approach 2:
The patent changes the mechanical parameter of the outer conductor from rigid to elastic by introducing spring-loaded contact elements. This parameter change enables the contact interface to dynamically adapt to manufacturing variations, maintaining optimal contact pressure and electrical connection quality despite increased mechanical tolerances in the overall connector assembly.
2Ease of manufacture
If multiple separate parts are used for outer conductor and base, then ease of manufacture improves, but electrical connections with oxide layers are created increasing PIM
Solution Approach 1:
The outer conductor and base are merged into a single monolithic component, eliminating the electrical connection interface between these two parts. This merging prevents the formation of oxide layers at the connection point, thereby reducing PIM generation while still allowing for practical manufacturing through monolithic fabrication processes.
3Reliability
If spring-loaded contact elements are used, then contact pressure and return loss improve, but device complexity increases
Solution Approach 1:
The outer conductor is designed as a flexible structure with spring-loaded contact elements that can elastically deform to maintain optimal contact pressure. This flexible design, achieved through parallel slits in the outer conductor, improves return loss and contact reliability while adding minimal structural complexity compared to traditional rigid connectors.
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 achieves low PIM by minimizing mechanical tolerances and eliminating electrical connections that could generate PIM, resulting in high return loss and precise positioning of connectors with low insertion forces and high contact pressures.
Implementation Method 1
the outer conductor (30) comprises a plurality of spring-loaded contact elements (36) which are oriented such, that they apply force in radial direction outwards of the center when mated
Data Source
AI summary
A coaxial connector includes a center conductor and an outer conductor coaxial with the center conductor. The outer conductor has a cylindrical shape with slits forming a plurality of spring loaded contact elements. The connector further has a base for mounting the coaxial connector and an outer housing. To improve passive intermodulation characteristics, the base, the slotted outer conductor and the outer housing are monolithically made in one piece.