Coaxial connector

A coaxial connector includes a center contact electrically connected to a conductor of a cable. The center contact extends along a contact axis oriented generally perpendicular to an axis of the conductor of the cable. An outer contact has a cavity and the center contact is disposed in the cavity. The outer contact has a separable interface end and a terminating end. The separable interface end and terminating end are oriented generally perpendicular to one another. A dielectric insert is received in the cavity. The dielectric insert has a bore that receives and holds the center contact. The dielectric insert has structural features extending axially along an exterior of the dielectric insert, with air gaps defined between the structural features. The structural features engage the outer contact to secure the dielectric insert in the cavity.

CROSS REFERENCE TO RELATED APPLICATIONS

This application relates to U.S. patent application having Appl. No. 13/330,978 and titled COAXIAL CONNECTOR filed on the same day, the subject matter of which is herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to coaxial connectors.

A typical coaxial connector has a metal outer shell, an inner dielectric insert, and a center contact to carry the signal which is secured within the inner dielectric insert. Coaxial connectors may be either plug connectors or jack connectors of either standard or reverse polarity configurations. Coaxial connectors may be either terminated to cable or terminated to a printed circuit board (PCB). For cable-mounted applications, the outer metal shell is crimped or soldered to the outer metal braid or solid metal jacket of the coaxial cable to provide an electrical connection between the shielding of the cable and the connector, while the center contact is crimped to the central conductor of the coaxial cable to provide connection for the signal pathway. For board-mounted applications, the outer metal shell is mechanically and electrically connected to a ground conductor of the PCB, while the center contact is mechanically and electrically connected to a signal conductor of the PCB.

Typical coaxial connectors are not without disadvantages. For instance, some coaxial connectors are right angle coaxial connectors where mating and terminating ends of the coaxial connectors are oriented generally perpendicular to one another. Such connectors are complex and costly to design and tool. It is difficult to maintain the impedance of such connectors between the mating and terminating ends as the signal path turns 90° within the connector. Additionally, typical coaxial connectors on the market are not platform designs, and do not enable customization or automated manufacturing. For example, the plug connectors are manufactured from multiple pieces or components specific to the plug connector design and the jack connectors are manufactured from multiple pieces or components specific to the jack connector design. Additionally, the cable-mounted connectors are manufactured from multiple pieces or components specific to the cable mounting design and the board-mounted connectors are manufactured from multiple pieces or components specific to the board mounting design. Moreover, the coaxial connectors are typically assembled by hand, which is time consuming. The pieces and components of the coaxial connectors are typically screw machined.

A need remains for a coaxial connector platform that allows for product design extensions, automated manufacturing and/or low cost.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a coaxial connector is provided including a center contact configured to be mated with a center contact of a mating connector and configured to be electrically connected to a conductor of a cable. The center contact extends along a contact axis oriented generally perpendicular to an axis of the conductor of the cable. An outer contact has a cavity and the center contact is disposed in the cavity. The outer contact has a separable interface end configured to be mated to the mating connector and a terminating end configured to be terminated to an end of the cable. The separable interface end and terminating end are oriented generally perpendicular to one another. A dielectric insert is received in the cavity. The dielectric insert has a bore that receives and holds the center contact. The dielectric insert has structural features extending axially along an exterior of the dielectric insert, with air gaps defined between the structural features. The structural features engage the outer contact to secure the dielectric insert in the cavity.

In another embodiment, a coaxial connector is provided including a center contact configured to be mated with a center contact of a mating connector and configured to be electrically connected to a conductor of a cable. The center contact has a mating end and a terminating end that includes an open-sided barrel with two paddles opposing one another across a gap. An outer contact has a cavity with the center contact disposed in the cavity. The outer contact has a separable interface end configured to be mated to the mating connector and a terminating end configured to be terminated to an end of the cable. The separable interface end and terminating end are oriented generally perpendicular to one another. A dielectric insert is received in the cavity that peripherally surrounds the barrel at the terminating end such that the dielectric insert is positioned between the center contact and the outer contact. The dielectric insert has structural features and air pockets being defined between the structural features. The size and shape of the structural features and air pockets are selected to provide a desired dielectric constant of dielectric between the center contact and the outer contact to tune the impedance of the coaxial connector.

In a further embodiment, a coaxial connector is provided including a center contact, a dielectric insert having a bore that receives and holds the center contact, and an outer contact having a cavity that receives the dielectric insert and the center contact. The outer contact has a separable interface end configured to be mated to a mating connector and a terminating end configured to be terminated to a coaxial cable. The separable interface end and terminating end are oriented generally perpendicular to one another. The outer contact includes a front housing defining the separable interface end and a rear housing defining the terminating end. The rear housing is interchangeable with the front housing to define differently shaped terminating ends for mating with differently sized cables.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates a coaxial connector system10formed in accordance with an exemplary embodiment. The coaxial connector system10may use different types of plug and jack coaxial connectors, such as different combinations of cable mounted connectors and board mounted connectors and/or different combinations of in-line and right angle connectors. The connections may be cable-to-cable, board-to-board or cable-to-board connections. Exemplary embodiments of versions of such connectors are illustrated inFIG. 1.FIG. 1illustrates a right angle, cable-mounted plug connector100, a right angle, board-mounted jack connector200, an in-line, cable-mounted plug connector300, an in-line, cable-mounted jack connector400, and an in-line, board-mounted jack connector500. The plug connectors are matable with the jack connectors. In an exemplary embodiment, the different versions of the coaxial connectors use interchangeable components across the product family to decrease the overall cost of the product family, such as tooling costs, stocking costs, and the like.

The plug connector100is terminated to a coaxial cable102. The jack connector200is terminated to a circuit board202. The plug connector300is terminated to a coaxial cable302. The jack connector400is terminated to a coaxial cable402. The jack connector500is terminated to a circuit board502. The plug connectors100,300are configured to be threadably coupled to one of the jack connectors200,400,500using internal threads on the plug connectors100,300and external threads on the jack connectors200,400,500. Alternative coupling means may be used in alternative embodiments.

FIGS. 2 and 3are front and rear exploded views of the plug connector100. The plug connector100includes a center contact110, a front dielectric insert112that holds the center contact110and an outer contact114that receives the dielectric insert112and the center contact110. The center contact110is configured to be terminated to a center conductor (not shown) of the coaxial cable102(shown inFIG. 1), either directly through direct engagement between the center contact110and the center conductor or indirectly through a separate pin contact terminated to the end of the center conductor that is then directly connected to the center contact110. The outer contact114is configured to be electrically connected to an outer conductor or cable shield (not shown) of the coaxial cable102, such as by crimping or soldering to the cable shield.

In an exemplary embodiment, the outer contact114is a multi-piece body formed from a rear housing116and a front housing118. In the illustrated embodiment, the front housing118defines a plug housing and may be referred to hereinafter as the plug housing118. The rear housing116may be a single-piece housing or may be a multi-piece housing. In an exemplary embodiment, the product family may include multiple different versions of the rear housings116that define a set of rear housings116adapted to be connected to different sized cables. Each of the rear housings116may be coupled to the same front housing118, thus reducing the total number of components in the product family.

The plug connector100includes a gasket120coupled to the front housing118to seal against the jack connector200(shown inFIG. 1) when mated thereto. The plug connector100includes a coupling nut122that is configured to be rotatably coupled to the front housing118. The coupling nut122has internal threads124for securing the plug connector100to the jack connector200.

The plug connector100includes a crimp barrel126coupled to the rear housing116. The crimp barrel126is used to crimp the plug connector100to the coaxial cable102. The crimp barrel126is used to mechanically and electrically connect the plug connector100to the coaxial cable102.

The center contact110extends along a contact axis128of the plug connector100between a separable interface end or mating end130and a non-separable terminating end132. The mating end130is configured to be mated with a corresponding contact of the jack connector200when the plug connector100is coupled thereto. Optionally, the center contact110may be selectively plated at the mating end130to enhance the performance and/or conductivity of the separable interface. In the illustrated embodiment, the mating end130defines a pin, however the center contact110may have a different mating interface in an alternative embodiment, such as a socket, such as to define a reverse polarity connector. In an exemplary embodiment, the center contact110is a stamped and formed contact. Stamped and formed contacts may be less expensive to manufacture than machined contacts. Stamped and formed contacts may have more complex shapes and features than machined contacts.

The terminating end132is configured to be terminated to a center conductor of the coaxial cable102. In an exemplary embodiment, the center contact110has an open sided barrel134at the terminating end132. The barrel134is configured to receive the center conductor of the coaxial cable102therein. Alternatively, the barrel134may receive another contact, such as a pin contact, that is terminated to the end of the conductor. In an exemplary embodiment, the barrel134includes a pair of paddles135opposing one another and separated by a gap136. The center conductor (or the pin contact) is received in the gap136between the paddles135. The paddles135press against the conductor (or the pin contact) to create an electrical connection therewith. The conductor (or the pin contact) may be terminated using a poke-in type of connection, which is advantageous for automation assembly processes. Optionally, the conductor may be soldered in the barrel134. In other alternative embodiments, center contact110may be terminated to the center conductor (or the pin contact) by other processes or methods, such as crimping, indenting, lancing, active beam termination, insulation displacement connection, and the like. By allowing the center contact110to be terminated to the center conductor in more than one manner, the same center contact110can be used for different applications and by different customers who prefer termination by either crimping or soldering. As such, the product family does not need to include different types of center contacts for different types of termination, thereby reducing the overall number parts for the product family and reducing the overall cost of the platform.

The paddles135and/or the gap136define an orientation feature of the center contact110that allows the center contact110to be held at a particular orientation with respect to a machine used to assemble the plug connector100. The paddles135and/or the gap136allow for automation of the assembly process of the plug connector100by allowing the center contact110to be held by a machine and inserted into the dielectric insert112.

The center contact110includes locking tabs138extending therefrom. The locking tabs138are deflectable. The locking tabs138are used to secure the center contact110in the dielectric insert112.

The front dielectric insert112is manufactured from a dielectric material, such as a plastic material. The dielectric material may be a composite material. The dielectric insert112has a bore140extending therethrough that receives and holds the center contact110. The dielectric insert112extends between a front142and a rear144. The bore140extends entirely through the dielectric insert112between the front142and the rear144. The bore140extends axially along the contact axis128of the plug connector100.

The dielectric insert112is generally tubular in shape and includes a plurality of structural features146, such as wings or tabs, extending radially outward from an exterior of the tubular dielectric insert112. In an exemplary embodiment, the structural features146extend axially along an exterior of the dielectric insert112. Having the structural features146extend axially allows the dielectric insert112to be molded rather screw machined, which may be a less expensive manufacturing of the dielectric insert112. Air gaps148are defined between the structural features146and introduce air (another type of dielectric) in the isolation area around the center contact110. In the illustrated embodiment, the structural features146extend only partially along the dielectric insert112. Optionally, the structural features146may extend along approximately half the axial length of the dielectric insert112. The structural features146may extend any axial distance along the dielectric insert112in alternative embodiments. In the illustrated embodiment, the structural features146are located proximate to the rear144, however the structural features146may be located at any axial position along the dielectric insert112.

The structural features146are used to secure the front dielectric insert112within the outer contact114. In an exemplary embodiment, the dielectric insert112is received within the front housing118and the structural features146engage the front housing118to secure the dielectric insert112in the front housing118. The structural features146may engage the outer contact114and hold the dielectric insert112by an interference fit therein. In an exemplary embodiment, the structural features146are tapered from a front150to a rear152of the structural features146to increase the diameter of the dielectric insert112at the rear144. As the dielectric insert112is loaded into the front housing118, the structural features146begin to engage the front housing118and create a tighter fit between the dielectric insert112and the front housing118as the dielectric insert112is further loaded into the front housing118.

In an exemplary embodiment, the size and shape of the structural features146are selected to provide a desired dielectric constant of the dielectric between the center contact110and the outer contact114. When the center contact110and dielectric insert112are loaded into the outer contact114, the center contact110is electrically isolated from the outer contact114by the material of the dielectric insert112and by air. The air and the dielectric insert112constitute the dielectric between the center contact110and the outer contact114. The dielectric constant is affected by the amount of material of the dielectric insert112as well as the amount of air. The material of the dielectric insert112has a dielectric constant that is greater than the dielectric constant of air. By selecting the size and shape of the dielectric insert112, including the structural features146, the impedance of the plug connector100may be tuned, such as to achieve an impedance of 50 Ohms or another target impedance. For example, a design having more plastic in the isolation area between the outer contact114and the center contact110(e.g., a thicker tube, wider structural features146, more structural features146, longer structural features146, and the like) may decrease the impedance, whereas providing more air may increase the impedance.

In an exemplary embodiment, the dielectric insert112includes an extension154extending rearward from the dielectric insert112. The extension154may be located generally along the top of the center contact110when loaded into the dielectric insert112. The extension154may be located in other locations in alternative embodiments. More than one extension154may be used in alternative embodiments. The extension154may extend into the rear housing116when the plug connector is assembled. The extension154may be positioned between the center contact110and the rear housing116to position a predetermined amount of dielectric material between the center contact110and the rear housing116, such as to control the impedance of the signal path along the extension154.

The front housing118extends between a front160and a rear162. The front housing118has a cavity164extending between the front160and the rear162. The cavity164receives the dielectric insert112and center contact110. In an exemplary embodiment, the front160of the front housing118defines a separable interface end166of the outer contact114. The rear162of the front housing118is configured to be coupled to the rear housing116.

The front housing118includes a barrel168at the rear162. A plurality of posts170extend rearward from the barrel168. As described in further detail below, the posts170are configured to be staked to the rear housing116to secure the front housing118to the rear housing116. For example, a special tool may be used to push down on the posts170to deform the posts170. The tool has a special shape to deform the posts and to force portions of the posts over the end of the rear housing116thereby securing the front housing118to the rear housing116. The front housing118may be coupled to the rear housing116by other means or processes in alternative embodiments.

The front housing118includes a flange172extending from an exterior of the front housing118. The flange172extends circumferentially around the front housing118. The flange172is positioned forward of the barrel168. The flange172is used to secure the coupling nut122to the front housing118.

The front housing118includes flat surfaces174on an exterior thereof. The flat surfaces174are configured to angularly orient the front housing118with respect to the rear housing116during coupling of the front housing118to the rear housing116. For example, the posts170may be oriented at a particular angular orientation with respect to the rear housing116during assembly. The flat surfaces174may be engaged by a machine used to assemble the plug connector100to hold the angular position of the front housing118for loading the front housing118into the rear housing116. Other features may be provided in alternative embodiments that allow the front housing118to be oriented with respect to the assembly machine for assembly of the plug connector100.

The rear housing116is configured to be interchangeably coupled to the front housing118with other differently sized/shaped rear housings, such as to mate to differently sized cables. The rear housing116includes a front180and a rear182. The rear housing116includes a bottom183. The bottom is oriented generally perpendicular with respect to the front180and the rear182. A cavity184extends through the rear housing116. The cavity184makes a 90° bend within the rear housing116. The cavity184is open at the front180, the rear182and the bottom183. The bottom183of the rear housing116defines a terminating end186of the outer contact114. When the rear housing116is coupled to the front housing118, the terminating end186is oriented generally perpendicular with respect to the separable interface end166. The plug connector100defines a right angle or 90° connector. The cable102extends generally at a right angle or 90° with respect to the center contact110. The signal path through the plug connector100is changed along the right angle path.

The rear housing116includes a tube188at the bottom183. The tube188is configured to interface with the cable102. For example, the tube188may receive the cable102. The tube188may be crimped or otherwise secured to the cable102. The rear housing116includes an interface body189at the front180. The interface body189is configured to interface with the front housing118. In the illustrated embodiment, the tube188and the interface body189are integrally formed. The tube188and the interface body189are a single-piece body. In alternative embodiments, the tube188and the interface body189may be separate pieces that are coupled together. Different rear housings116may be defined as having different sized tubes188(e.g. different lengths, different diameters, different shapes, and the like). In the single-piece version, the entire rear housing116may be removed from the front housing118and replaced with a different rear housing116having a different sized tube188. In the multi-piece version, the same interface body189is utilized to couple to the front housing118, but differently sized tubes188are interchangeably coupled to the bottom of the interface body189.

The rear housing116includes a rim190proximate to the front180. The interface body189forms the rim190. The rim190defines a chamber192that receives the front housing118. The rim190and chamber192define a housing interface194at the front180of the rear housing116. The front housing118is coupled to the housing interface194.

In an exemplary embodiment, the rear housing116includes a plurality of openings196at a rear or bottom of the chamber192. When the front housing118is coupled to the rear housing116, the barrel168of the front housing118is received in the chamber192and the posts170of the front housing118extend through corresponding openings196in the rear housing116. The posts170extend entirely through the openings196and may be staked from behind the rim190to secure the front housing118to the rear housing116. For example, the ends of the posts170are located in the cavity184and are staked from inside the cavity184. A tool or machine may be inserted into the cavity184through the rear182to stake the posts170to the rear housing116. Alternatively, the ends of the posts170may be accessible from the exterior of the rear housing116.

The rear housing116includes an inner shield197in the cavity184and/or defining part of the cavity184. The inner shield197may be integrally formed with the rear housing116, such as during a common molding or forming process. Alternatively, the inner shield197may be separate from the rear housing116and loaded into the rear housing116. The inner shield197may be shaped complementary to the shape of the barrel134of the center contact110, with the inner shield197being spaced apart from the barrel134by a predetermined distance selected to control the impedance of the signal path through the plug connector100. The size and shape of the inner shield197may be selected to tune or control the impedance, such as to achieve a target impedance along such portion of the rear housing116. For example, the size and shape of the inner shield197may be selected to allow a certain volume of air to be positioned between the inner shield197and the center contact110.

The interior of the inner shield197defines a portion of the cavity184and is sized to ensure that the barrel134does not touch (e.g. electrically short) the center contact110. In an exemplary embodiment, a gap198is defined between the inner shield197and the interior surface of the rear housing116. The gap198provides a space for a staking tool to engage the posts170to stake the front housing118to the rear housing116.

FIG. 4is a cross-sectional view of the plug connector100showing the center contact110loaded into the dielectric insert112and outer contact114. During assembly, the gasket120is loaded onto the front160of the front housing118. The gasket120is seated against the flange172. The coupling nut122is loaded onto the rear162of the front housing118. The coupling nut122extends forward of the front160of the front housing118. The coupling nut122defines a chamber that receives a portion of the jack connector200(shown inFIG. 1). The coupling nut122includes a lip199that engages the flange172to stop forward loading of the coupling nut122onto the front housing118. The lip199is captured between the flange172and the rim190of the rear housing116to axially position the coupling nut122with respect to the front housing118. The coupling nut122is rotatable with respect to the front housing118. The flange172limits forward movement of the coupling nut122and the rim190limits rearward movement of the coupling nut122.

The dielectric insert112is inserted into the front housing118through the rear162. The structural features146engage the front housing118to hold the dielectric insert112in the cavity164by an interference fit. In an exemplary embodiment, the rear144of the dielectric insert112is positioned forward of the rear162of the front housing118. The front housing118is coupled to the rear housing116such that the rear162engages the wall defining the bottom of the chamber192. The rear162of the front housing118is received in the chamber192(shown inFIG. 2). The rim190circumferentially surrounds the rear162of the front housing118. The wall at the rear or bottom of the chamber192is positioned behind the dielectric insert112to ensure that the dielectric insert112remains in position in the front housing118. The posts170(shown inFIG. 2) extend into the rear housing116and are staked inside the rear housing116.

The center contact110is loaded along the contact axis128in a loading direction, shown by the arrow A. The center contact110may be loaded into the outer contact114at any stage of the assembly process. For example, the center contact110may be loaded into the dielectric insert112prior to the dielectric insert112being loaded into the front housing118. Alternatively, the center contact110may be loaded into the dielectric insert112after the front housing118and rear housing116are coupled together.

In the illustrated embodiment, the rear housing116is a one-piece body with the tube188formed integral with the interface body189. The cavity in the tube188is open to the cavity in the interface body189to allow the cable102to extend into the cavity in the interface body189for termination to the center contact110. An exposed conductor660of the cable102is pressed into the center contact110between the paddles135. The paddles135make electrical connection with the center contact110. Optionally, the conductor660may be soldered to the center contact110to make an electrical and mechanical connection with the center contact110. In an alternative embodiment, a pin contact may be terminated to the center conductor660and the pin contact may be inserted into the center contact110between the paddles135to make an electrical connection between the center conductor660and the center contact110. The tube188is sized to snuggly fit the cable102therein. The crimp barrel126is used to mechanically and/or electrically connect the tube188to the cable102. The crimp barrel126may provide strain relief.

FIGS. 5 and 6show alternative plug connectors100aand100bhaving different sized tubes188a,188b, respectively, which are sized differently than the tube188(shown inFIG. 4). The tubes188a,188bare used with differently sized cables102a,102b.FIG. 5also illustrates a pin contact662aterminated to an end of the conductor660a. The pin contact662aextends into the cavity184to engage the center contact110. The pin contact662aextends along a pin contact axis664a, which may be oriented generally perpendicular to the contact axis128. The paddles135make a mechanical and electrical connection to the pin contact662a.

FIGS. 7,8and9show alternative plug connectors100c,100dand100e, respectively. The plug connectors100c,100d,100ehave two-piece rear housings116c,116d,116e. The tubes188c,188d,188eare separate and discrete pieces from the interface bodies189c,189d,189e. In an exemplary embodiment, the interface bodies189c,189d,189eare identical to one another or are the same part, thus reducing the total number of different parts for the product family. The tubes188c,188d,188eare all able to attach to the same interface body.

The features of the interface bodies189c,189d,189ewill be described with reference to the interface body189c, however the other interface bodies189d,189emay include similar or identical features. The interface body189c, at a bottom thereof, includes a barrel670ccircumferentially surrounding the cavity184c. A shroud672cperipherally surrounds the barrel670c. The shroud672cis generally box-shaped and defines an outer perimeter of the interface body189cat the bottom. A circumferential groove674cis defined between the barrel670cand the shroud672c.

The features of the tubes188c,188d,188ewill be described with reference to the tube188c, however the other tubes188d,188emay include similar or identical features. The tube188cincludes a mounting block676cand an extension678c. The mounting block676cis secured to the interface body189c. In an exemplary embodiment, the mounting block676cis received in the groove674cand mechanically secured therein. For example, crush ribs may be provided on the barrel670cor the tube188c. The extension678cextends downward from the mounting block676cand the interface body189cto receive the cable102c.

FIG. 10is an exploded view of an alternative plug connector100f. The plug connector100fincludes similar features as the plug connector100(shown inFIGS. 2 and 3), which will be identified with like reference numerals. However the plug connector100fincludes a rear dielectric insert113fin addition to the center contact110, front dielectric insert112(shaped slightly different to accommodate the rear dielectric insert113) and outer contact114. The outer contact114includes the front housing118and a rear housing116f, similar to the rear housing116(shown inFIGS. 2 and 3), however the rear housing116fdoes not include the inner shield197(shown inFIGS. 2 and 3).

The rear dielectric insert113fis manufactured from a dielectric material, such as a plastic material. The dielectric material may be a composite material. The dielectric insert113fhas a bore640extending therethrough that receives and/or holds the center contact110. The dielectric insert113fextends between a front642and a rear644. The bore640extends entirely through the dielectric insert113fbetween the front642and the rear644.

The dielectric insert113fis generally tubular in shape and includes a plurality of structural features646, such as walls or tabs, surrounding the bore640. The dielectric insert113falso includes air pockets648open to the bore640. The structural features646define the air pockets648. The air pockets648introduce air (another type of dielectric) in the isolation area around the center contact110. The air pockets648are positioned in the vicinity of the paddles135. The air pockets648provide a space for the paddles135to deflect or spread outward, such as when the conductor of the cable102(or the pin contact) is inserted into the center contact110.

The dielectric insert113fincludes a radial opening650open to the bore640. The radial opening650receives the conductor of the cable102(or the pin contact) therethrough during assembly such that the conductor (or pin contact) may be coupled to the center contact110. In the illustrated embodiment, the radial opening650is provided at a bottom of the dielectric insert113f.

The dielectric insert113fincludes a channel652extending along an exterior of the dielectric insert113f. The channel652defines a keying or orientation feature of the dielectric insert113f. A rib654of the outer contact114extends into the channel652to orient the dielectric insert113fin the rear housing116f. Other types of keying features may be used in alternative embodiments. The structural features646, channel652and/or the radial opening650individually or together allow for automation of the assembly process of the plug connector100fby allowing the dielectric insert113fto be held by a machine and inserted into the rear housing116f.

The dielectric insert113fincludes crush ribs656to secure the dielectric insert113fin the rear housing116f. Other securing features may be used in alternative embodiments. The dielectric insert113fmay include similar structural features and air gaps along the exterior thereof as the dielectric insert112.

The dielectric insert113fincludes pockets658in the front642. The pockets658receive the posts170when the plug connector100fis assembled. The engagement between the posts170and the pockets658may be used to help align and/or resist rotation of the dielectric insert113fin the rear housing116fwhen assembled.

In an exemplary embodiment, the size and shape of the structural features646and corresponding air pockets648are selected to provide a desired dielectric constant of the dielectric between the center contact110and the outer contact114. When the center contact110and dielectric insert113fare loaded into the outer contact114, the center contact110is electrically isolated from the outer contact114by the material of the dielectric insert113fand by air. The air and the dielectric insert113fconstitute the dielectric between the center contact110and the outer contact114. The dielectric constant is affected by the amount of material of the dielectric insert113fas well as the amount of air. The material of the dielectric insert113fhas a dielectric constant that is greater than the dielectric constant of air. By selecting the size and shape of the dielectric insert113f, including the structural features646, the impedance of the plug connector100fmay be tuned, such as to achieve an impedance of 50 Ohms or another target impedance. For example, a design having more plastic in the isolation area between the outer contact114and the center contact110(e.g., a thicker tube, wider structural features646, more structural features646, longer structural features646, and the like) may decrease the impedance, whereas providing more air may increase the impedance. Because of the non-cylindrical shape of the barrel134, such as due to the paddles135, the shape of the bore640, defined by the structural features646and air pockets648, is irregular. The air pockets648around the paddles135provide extra air around the paddles135and raise the impedance of the signal path in the area along the paddles135.

FIGS. 11 and 12are front and rear exploded views of the jack connector200. The jack connector200is configured to be mounted to the printed circuit board (PCB)202. The jack connector200is configured to be electrically coupled with the plug connector100(shown inFIG. 1).

The PCB202includes first and second surfaces203,204. A signal via205extends through the PCB202between the first and second surfaces203,204. The signal via205may be plated and electrically connected to a signal trace of the PCB202to define a signal conductor of the PCB202. The signal via205is configured to be electrically connected to a board contact209of the jack connector200.

The PCB202includes ground vias206extending through the PCB202between the first and second surfaces203,204. The ground vias206surround the signal via205. The ground vias206may be plated and electrically connected to one or more ground planes of the PCB202to define ground conductors of the PCB202. The ground vias206are configured to be electrically connected to a circuit board mount215of the jack connector200.

In an exemplary embodiment, the board contact209and circuit board mount215are through-hole mounted to the PCB202by plugging the board contact209and circuit board mount215into the signal via205and ground vias206, respectively. The jack connector200may be terminated to the PCB202by alternative means, such as by surface mounting the board contact209and/or circuit board mount215to the PCB202. For example, rather than the signal via205and ground vias206, the circuit board202may include ground pads with the board contact209and the circuit board mount215being surface mounted to the pads, such as by soldering to the pads.

The jack connector200includes the board contact209and a center contact210configured to be coupled together to define a signal path through the jack connector200. The jack connector200includes a bottom dielectric insert211and a front dielectric insert212(optionally a rear dielectric insert (not shown), similar to the rear dielectric insert113(shown inFIG. 10) may be used, such as when the jack connector200includes a two-part outer contact) that are used to hold the board contact209and/or the center contact210, respectively. The jack connector200includes an outer contact214that receives the dielectric inserts211,212and the contacts209,210. The jack connector200includes the circuit board mount215, which is coupled to the outer contact214. The circuit board mount215and the outer contact214are electrically connected together and define a ground path or shield around the signal path. The circuit board mount215is used to mount the jack connector200to the PCB202.

In an exemplary embodiment, the dielectric insert212may be identical to the dielectric insert112(shown inFIGS. 2 and 3). As such, the product family (both plug and jack connectors100,200) does not need to include different types of dielectric inserts for the plug and jack connectors100,200, thereby reducing the overall number parts for the product family and reducing the overall cost of the platform.

The board contact209is configured to be terminated to the PCB202, such as to a signal conductor of the PCB202. The board contact209is mechanically and electrically connected to the center contact210within the outer contact214. The center contact210is configured to be electrically connected to a center contact of a plug connector, such as the center contact110of the plug connector100(both shown inFIGS. 2 and 3). The outer contact214is configured to be electrically connected to the PCB202, via the circuit board mount215, to a ground conductor of the PCB202.

In an exemplary embodiment, the outer contact214is a single-piece body having a rear housing portion216and a front housing portion218integrally formed together. In alternative embodiments, the outer contact214may be a multi-piece body with the pieces coupled together. In the illustrated embodiment, the outer contact214defines a jack housing and may be referred to hereinafter as the jack housing218. The jack housing218has external threads224for securing the jack connector200to the plug connector100. The rear housing portion216receives the bottom dielectric insert211to support the board contact209.

The center contact210extends along a contact axis228of the jack connector200between a separable interface at a mating end230and a non-separable terminating end232. The contact axis228may be generally perpendicular to a contact axis233of the board contact209. The mating end230is configured to be mated with the mating end130(shown inFIG. 2) of the center contact110(shown inFIG. 2) of the plug connector100when the jack connector200is coupled thereto.

The terminating end232is configured to be terminated to the board contact209. In an exemplary embodiment, the center contact210has an open-sided barrel234at the terminating end232. Optionally, the barrel234may be similar or identical to the barrel134(shown inFIGS. 2 and 3). The barrel234is configured to receive the board contact209to electrically connect the board contact209to the center contact210. In the illustrated embodiment, the board contact209defines a pin contact, however the board contact209may have other configurations in alternative embodiments. The board contact209includes a terminating end233that is received in the plated signal via205of the PCB202to electrically connect the board contact209to the PCB202. The terminating end233may be a compliant section held in the PCB202by an interference fit. Optionally, the terminating end233may be soldered to the PCB202.

In an exemplary embodiment, the barrel234includes a pair of paddles235opposing one another and separated by a gap236. The board contact209is received in the gap236between the paddles235. The paddles235press against the board contact209to create an electrical connection therewith.

The dielectric insert211defines a bottom dielectric insert that is loaded into the bottom of the outer contact214. The dielectric insert211holds the board contact209. The dielectric insert212defines a front dielectric insert that is loaded into the outer contact214. The dielectric insert212holds the center contact210. The dielectric inserts211,212are similar to one another. The dielectric insert212will be described in detail, but the dielectric insert211may include similar features and components.

The dielectric insert212has a bore240extending therethrough that receives and holds the center contact210. The dielectric insert212extends between a front242and a rear244. The bore240extends entirely through the dielectric insert212between the front242and the rear244. The bore240extends axially along the contact axis228of the jack connector200.

The dielectric insert212is generally tubular in shape and includes a plurality of structural features246extending radially outward from an exterior of the tubular dielectric insert212(the structural features of the dielectric insert212may be differently sized or shaped). Air gaps248are defined between the structural features246. The structural features246are used to secure the dielectric insert212within the outer contact214by an interference fit therein. In an exemplary embodiment, the structural features246are tapered from a front250to a rear252of the structural features246. In an exemplary embodiment, the size and shape of the structural features246are selected to provide a desired dielectric constant of the dielectric between the center contact210and the outer contact214.

The outer contact214extends between a front260and a rear262. The outer contact214has a bottom263. The bottom263is configured to be mounted to the PCB202. The bottom263is oriented generally perpendicular with respect to the front260and the rear262. The circuit board mount215is coupled to the bottom263. The outer contact214has a cavity264extending between the front260and the rear262. The cavity264extends to the bottom263. The cavity264turns 90° within the outer contact214to create a path between the front260and the bottom263. The cavity264receives the dielectric insert212and center contact210. The cavity264receives the dielectric insert211and the board contact209. In an exemplary embodiment, the front260of the outer contact214defines a separable interface end266of the outer contact214. The bottom263of the outer contact214defines a terminating end268of the outer contact214. The terminating end268is oriented generally perpendicular with respect to the separable interface end266. The jack connector200defines a right angle or 90° connector. The signal path through the jack connector200is changed along the right angle path.

The circuit board mount215is configured to mechanically and electrically connect the outer contact214to the PCB202. The circuit board mount215includes a top700and a bottom702. A cylindrical rim704surrounds a cavity706extending between the top700and the bottom702. Mounting legs708extend from the bottom702of the rim704. The mounting legs708are terminated to the PCB202to secure the circuit board mount215to the PCB202. The mounting legs708may be received in the plated ground vias206in the PCB202to mechanically and electrically connect the circuit board mount215to the PCB202. The mounting legs708may be press fit into the vias in the PCB202to mechanically and/or electrically connect the circuit board mount215to the PCB202. The rim704includes tabs710at the bottom702. The tabs710are used to secure the circuit board mount215in the outer contact214.

FIG. 13is a bottom view of the jack connector200showing the circuit board mount215coupled to the outer contact214. In an exemplary embodiment, the outer contact214includes a shroud720surrounding a barrel722, with a groove724defined between the shroud720and the barrel722. The rim704is loaded into the groove724. The tabs710are pressed against the shroud720to hold the circuit board mount215therein by an interference fit.

In an exemplary embodiment, channels726are provided at the bottom of the outer contact214that extend between the groove724and the exterior of the shroud720. In the illustrated embodiment, the channels726are provided at the corners of the shroud720, however the channels726may be provided at other positions in alternative embodiments. The mounting legs708extend into corresponding channels726. The mounting legs708are secured in the channels726. In an exemplary embedment, the shroud720, at the edges of the channels726, may be staked to the mounting legs708to secure the mounting legs708in the channels726. Other means or processes may be used to mechanically and electrically couple the circuit board mount215to the outer contact214.

FIG. 14is a cross-sectional view of the jack connector200showing the center contact210loaded in the dielectric insert212and outer contact214. The board contact209is loaded in the dielectric insert211and engages the center contact210.

FIG. 15is a side view of an alternative jack connector200a. The jack connector200ais similar to the jack connector200(shown inFIGS. 11 and 12), and like components are identified with like reference numerals. The jack connector200aincludes an outer contact214a. The outer contact214amay be similar to the outer contact214, however the outer contact214ais a multi-piece body. The outer contact214aincludes a front housing218aand a rear housing216a.

FIG. 16is a cross sectional view of the jack connector200ahaving an alternative circuit board mount215a. The circuit board mount215aincludes surface mount legs750, rather than the compliant, through-hole mounting legs708of the circuit board mount215(shown inFIGS. 11 and 12).

The jack connector200aincludes a front dielectric insert212aand a rear dielectric insert213a. The front dielectric insert212amay be substantially similar to the front dielectric insert212(shown inFIGS. 11 and 12). The rear dielectric insert213amay be substantially similar to the rear dielectric insert113f(shown inFIG. 10).