Shaped Dielectric Insert Impedance Control Electrical Connector
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Solution Overview
Problem
Existing methods for controlling impedance in electrical connectors, such as BNC connectors, are limited in effectively achieving desired impedance values at the engagement end/interface, leading to unwanted signal reflections.
Innovation Solution
The electrical connector design includes a dielectric insert with a recess surface and a dielectric rim that defines an impedance-control space surrounding the electrical contact, using a dielectric material like PTFE or nylon to achieve a predetermined impedance of 50 or 75 ohms by creating an air dielectric environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a neck is provided to immediately surround the socket for mechanical support, then mechanical strength is improved, but impedance control at the engagement end deteriorates
Solution Approach 1:
The dielectric insert is divided into distinct functional zones: a neck portion for mechanical support and an engagement end portion for impedance control. This segmentation allows each zone to optimize its specific function without interfering with the other, resolving the contradiction between mechanical strength and impedance control.
Solution Approach 2:
Different portions of the dielectric insert are given different geometrical characteristics tailored to their specific functions. The neck has a configuration optimized for mechanical support, while the engagement end has a configuration optimized for impedance control. This local differentiation allows simultaneous optimization of both mechanical strength and impedance control.
2Ease of manufacture
If the engagement end has a planar surface perpendicular to the axis, then manufacturing is simplified, but impedance control at the interface deteriorates
Solution Approach 1:
The engagement end of the dielectric insert features a curved surface that transitions from the planar surface, creating a non-uniform dielectric configuration specifically at the interface region. This localized geometrical modification improves impedance control without requiring complete redesign of the entire engagement end, maintaining reasonable manufacturability.
Solution Approach 2:
The solution introduces curvature in the engagement end surface, adding a dimensional variation to the otherwise planar geometry. This curvature creates the necessary dielectric profile for impedance control while still being manufacturable using standard molding or machining processes.
3Reliability
If air dielectric is used to achieve desired impedance, then impedance control is improved, but mechanical support capability deteriorates
Solution Approach 1:
The dielectric insert separates the mechanical support function (neck portion) from the impedance control function (engagement end portion with air dielectric configuration). The neck provides robust mechanical support while the engagement end creates the air dielectric environment needed for precise impedance control, allowing both functions to coexist without compromise.
Solution Approach 2:
The dielectric insert acts as an intermediary structure that mediates between the mechanical support requirements and the electromagnetic field requirements. It provides the mechanical interface while simultaneously creating the air dielectric environment, serving both mechanical and electromagnetic functions through its specific geometrical configuration.
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
This design effectively controls impedance, reducing signal reflections and ensuring reliable connectivity by maintaining a consistent impedance across the connector interface.
Implementation Method 1
using a dielectric material like PTFE or nylon to achieve a predetermined impedance of 50 or 75 ohms by creating an air dielectric environment
Data Source
AI summary
Electrical connector that includes a connector housing having mating and terminating ends. The connector housing has a housing cavity and a leading edge at the mating end that defines an opening to the housing cavity. A central axis extends through the housing cavity between the mating and terminating ends. The electrical connector also includes a dielectric insert within the housing cavity and an electrical contact that is held by the insert along the central axis. The insert has a recess surface that faces the mating end and extends a radial distance, outward from the electrical contact. The insert includes a dielectric rim that projects from the recess surface toward the mating end. The dielectric rim surrounds: and is radially spaced from at least a portion of the electrical contact. The dielectric rim and the recess surface define an impedance-control space that surrounds at least the portion of the electrical contact.