Right-Angle PCB-to-Cable Connector With Dielectric Signal Transition
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Solution Overview
Problem
Microwave frequency connectors with right-angle housings and metallic center contacts perform poorly above 10 GHz due to the right-angle transition to a printed circuit board, limiting their effectiveness in high-frequency applications.
Innovation Solution
The development of connector assemblies with a metallic housing, first dielectric, and alignment dielectric that guide a cable center conductor through an angle from 0° to 90° transition to a printed circuit board, utilizing a method that includes inserting a cable into a housing, looping an alignment tool around the center conductor, and bending it to a 90° orientation, allowing for efficient high-frequency signal transmission up to 65 GHz with low insertion and return losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a right-angle transition to PCB is used in microwave frequency connectors, then the connector structure is compact and easy to manufacture, but the signal transmission performance deteriorates above 10 GHz due to high insertion and return losses
Solution Approach 1:
The connector is divided into distinct functional segments: a right-angle housing for compact mounting, a separate dielectric component with integrated center contact that provides the gradual transition path, and a PCB interface section. This segmentation allows each component to be optimized independently while maintaining overall performance.
Solution Approach 2:
A dielectric component acts as an intermediary element between the right-angle housing and the PCB center contact. This dielectric provides a gradual geometric transition that guides the signal from the axial cable connection through a smooth curve to the perpendicular PCB interface, reducing impedance discontinuities and improving signal transmission above 10 GHz.
2Reliability
If a gradual angle transition (0° to 90°) is implemented to improve signal transmission above 10 GHz, then insertion and return losses are reduced, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The dielectric component merges multiple functions into a single element: it provides mechanical support for the center contact, defines the gradual transition geometry, provides electrical insulation, and interfaces with both the housing and PCB. This consolidation simplifies manufacturing compared to assembling multiple separate components.
Solution Approach 2:
The dielectric component is pre-formed with the gradual transition geometry integrated into its structure before assembly. The center contact is pre-positioned within the dielectric, and alignment features are pre-configured to guide proper installation, reducing assembly complexity despite the complex geometry.
3Reliability
If multiple components are used to achieve gradual transition and improve signal performance, then frequency operation up to 65 GHz is enabled, but the connector profile increases and compactness is reduced
Solution Approach 1:
The center contact is nested within the dielectric component, which is in turn nested within the right-angle housing. This nested arrangement minimizes the overall connector profile by eliminating gaps and unnecessary spacing between components, allowing high-frequency performance in a compact form factor.
Solution Approach 2:
The gradual transition from 0° to 90° is achieved by utilizing three-dimensional spatial curvature within the compact housing volume. The dielectric creates a smooth curved path that transitions the center contact from axial to perpendicular orientation, enabling gradual transition performance without increasing the connector's external dimensions.
Data Source
AI summary
A connector assembly includes housing for storing components of the connector assembly. The connector assembly further includes a cable including a cable center conductor, wherein the cable center conductor is configured as a signal conductor. The connector assembly also includes a first dielectric and an alignment dielectric. Each of the first dielectric and the alignment dielectric includes a path to guide the cable center conductor through an angle to a printed circuit board as the cable is axially inserted into the housing.