RF Crimp Contact Geometry for Impedance-Matched Connections
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Solution Overview
Problem
Existing crimp connections in RF connectors face challenges in maintaining homogeneous impedance across the entire transmission system, particularly due to deviations caused by crimping processes and air gaps, complicating the connection process and requiring additional components for impedance matching.
Innovation Solution
A crimp contact with a crimp barrel featuring a crimp region and an impedance matching region, where the crimp shoulders are bent to form a longitudinal seam, and the outer surface of the crimp barrel has a gradual expansion to compensate for impedance deviations, ensuring reliable electrical contact without additional components or adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional crimp connection is used to establish electrical contact, then the connection process is simple and cost-effective, but impedance deviations occur due to crimping process tolerances and air gaps
Solution Approach 1:
The crimp barrel is designed with different geometric characteristics in different regions: a first region with a first outer diameter for standard crimping function, and a second region with a second outer diameter specifically optimized for impedance matching. This local differentiation allows the crimp connection to maintain both manufacturing simplicity and impedance consistency by addressing the impedance issue in a specific localized area without complicating the overall crimping process.
2Manufacturing precision
If additional components are added to compensate for impedance deviations, then impedance matching is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The impedance matching function is merged into the crimp barrel itself by creating a second region with a specific outer diameter. This integration eliminates the need for separate impedance matching components such as additional dielectric elements or geometric modifications to the connector housing, thereby maintaining impedance matching performance while reducing overall device complexity and manufacturing cost.
Solution Approach 2:
The crimp barrel is designed to perform multiple functions: it provides the mechanical crimping function through its first region, and simultaneously provides impedance matching through its second region. This multi-functionality eliminates the need for separate dedicated impedance matching components, simplifying the overall connector structure while achieving both mechanical connection and electrical performance requirements.
3Manufacturing precision
If the crimp barrel geometry is modified to match impedance, then RF performance is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The solution involves changing the geometric parameter (outer diameter) of the crimp barrel in a specific region to achieve impedance matching. By carefully selecting the second outer diameter in the second region, the impedance is optimized for high-frequency signal transmission. This parameter change can be integrated into existing stamping or extrusion processes, maintaining ease of manufacture while achieving the desired electrical performance.
Data Source
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AI summary
The present invention relates to a crimp contact for making a crimp connection between an inner conductor terminal of a connector and an electrical conductor, and a crimp connection including such a crimp contact. Furthermore, the invention relates to a method for making a crimp connection. In particular, the crimp contact (100) includes a crimp barrel (110) having at least one crimp base (112) and at least two crimp shoulders (114), the crimp barrel (110) having a crimp region (118) and an impedance matching region (120). At least in the crimp region (118), the at least two crimp shoulders (114) are arranged to enable, upon forming a longitudinal seam (122), to be bent around an electrical conductor (102), and in the impedance matching region (120), at least a portion of an outer surface of the crimp barrel (110) has a gradual expansion (128) in the direction of the longitudinal seam (122).