Patent Publication Number: US-2021195733-A1

Title: Interconnect device

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application and claims priority to U.S. patent application Ser. No. 16/259,889 entitled “INTERCONNECT DEVICE” filed on Jan. 28, 2019, the content of which is incorporated herewith in its entirety. 
    
    
     BACKGROUND 
     Statement of the Technical Field 
     The present disclosure relates generally to electronic systems. More particularly, the present disclosure relates to interconnect devices for electronic systems. 
     DESCRIPTION OF THE RELATED ART 
     Interconnect devices are well known in the art. Some of these conventional interconnect devices are Commercial Off The Shelf (“COTS”) connectors used in Radio Frequency (“RF”) applications. These COTS connectors are referred to as RF connectors. Some of the RF connectors are VITA compliant. However, none of these RF connectors meet all of the requirements for certain applications. For example, some of the RF connectors have flexible cable interfaces, have edge launch connectors in multiple planes, have a relatively low density pin count and/or have relatively poor isolation between adjacent pins which is/are not desirable in certain applications. 
     SUMMARY 
     The present disclosure concerns implementing systems and methods for making an interconnect device for electronic circuits. The methods comprise: fabricating a housing as a single 3D printed part having a plurality of apertures with bend angles less than ninety degrees; inserting wires into the plurality of apertures of the housing; and establishing electrical connections respectively between (A) the wires and a plurality of first socket adaptors and (B) the wires and a plurality of second socket adaptors. 
     In some scenarios, the apertures are designed such that the wires inserted therein all have a same length. Phase matching is provided between sets of a first socket adaptor, a second socket adaptor and a wire. The first socket adaptors are of a same type as the second socket adaptors. A center axis of each first socket adaptor is perpendicular to a center axis of each second socket adaptor. The first socket adaptors and/or the second socket adaptors are arranged as a two dimensional grid of socket adaptors in a given area of the housing. A spacing between adjacent ones of the plurality of first socket adaptors and a spacing between adjacent ones of the plurality of second adaptors are selected to provide an optimized isolation between sets of first socket adaptors, second socket adaptors and wires. 
     In those or other scenarios, each wire comprises at least one end portion with a first diameter greater than a second diameter of center portion thereof. The end portion engages a sidewall of a respective aperture so that the wire maintains a certain position relative to respective first and second socket adaptors throughout use of the interconnect device. The interconnect device may be VITA compliant, and the electronic circuits may comprise radio circuitry. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present solution will be described with reference to the following drawing figures, in which like numerals represent like items throughout the figures. 
         FIG. 1  is a perspective view of a conventional RF connector. 
         FIG. 2  is an illustration that is useful for understanding the architecture of elongate through holes formed in the RF connector of  FIG. 1 . 
         FIG. 3  is a perspective view of an electronic device comprising a circuit board with an interconnect device coupled thereto. 
         FIG. 4  is a perspective view of the electronic device of  FIG. 3  with the interconnect device shown in a transparent form. 
         FIG. 5  is a bottom perspective view of the interconnect device shown in  FIGS. 3-4 . 
         FIG. 6  is a top perspective view of the interconnect device shown in  FIG. 5 . 
         FIG. 7  is a perspective view of the interconnect device shown in  FIG. 5  with a housing shown in a transparent form. 
         FIG. 8  is a perspective view of the interconnect device shown in  FIGS. 3-7  with a first portion cut-away therefrom that is useful for understanding first internal apertures of the housing. 
         FIG. 9  is a side view of the interconnect device shown in  FIGS. 3-7  with the first portion cut-away therefrom. 
         FIG. 10  is a perspective view of the interconnect device shown in  FIGS. 3-7  with a second portion cut-away therefrom that is useful for understanding second internal apertures of the housing. 
         FIG. 11  is a side view of the interconnect device shown in  FIGS. 3-10  with the second portion cut-away therefrom. 
         FIG. 12  is a graph showing high isolation between adjacent pins or socket adaptors of an interconnect device. 
         FIG. 13  is a flow diagram of an illustrative method for fabricating an interconnect device. 
     
    
    
     DETAILED DESCRIPTION 
     It will be readily understood that the components of the embodiments as generally described herein and illustrated in the appended figures could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the present disclosure, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated. 
     The present solution may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the present solution is, therefore, indicated by the appended claims rather than by this detailed description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. 
     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present solution should be or are in any single embodiment of the present solution. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present solution. Thus, discussions of the features and advantages, and similar language, throughout the specification may, but do not necessarily, refer to the same embodiment. 
     Furthermore, the described features, advantages and characteristics of the present solution may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize, in light of the description herein, that the present solution can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the present solution. 
     Reference throughout this specification to “one embodiment”, “an embodiment”, or similar language means that a particular feature, structure, or characteristic described in connection with the indicated embodiment is included in at least one embodiment of the present solution. Thus, the phrases “in one embodiment”, “in an embodiment”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     As used in this document, the singular form “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” means “including, but not limited to”. 
     An ability to 3D print precision metal parts has opened up new opportunities for fabricating electronic components. Accordingly, the present solution generally concerns an interconnect device with at least one 3D printed part formed of a conductive material (e.g., aluminum). The 3D printed part comprises a housing for wires and socket adaptors. The housing has a plurality of elongate through holes formed therein for receiving and housing the wires. Notably, each elongate through hole has a curved portion with an angle less than ninety degrees. Such curved elongate through holes have not been manufactured in the past since conventional manufacturing and machining technologies only allow for cross drilling straight holes so as to form an aperture with a curved portion having an angle equal to ninety degrees. 
     The interconnect device of the present solution is superior to conventional interconnect devices. In this regard, it should be understood that the present interconnect device has the following features: high density pin or socket adaptor count in a given area; high isolation between adjacent pins or socket adaptors (e.g., as shown in the graph of  FIG. 12 ); a one circuit card application; a simpler design; less costly to incorporate into a product; an x-y grid of connectors or socket adaptors (i.e., connectors or socket adaptors in a single plane which facilitates the one circuit card application) on each of the two interfaces of interconnect device; interface elements (e.g., socket adaptors) that are all the same; no flexible cable connections; VITA compliant (e.g., VITA 67.3 compliant); and/or phase matching between electrical connectors (e.g., sets of two socket adaptors and one wire). Conventional interconnect devices do not each have all of the listed features, and therefore are inferior to the present solution. 
     One such conventional interconnect device will now be briefly described in relation to  FIGS. 1-2 . As shown in  FIG. 1 , the interconnect device comprises an RF connector  100 . The RF connector  100  comprises a first interface formed of a plurality of leads  102  that pass through conductive vias of a Printed Circuit Board (“PCB”) (not shown) and a second interface formed of a plurality of socket adaptors  104  for connecting the PCB to another electronic element. The leads  102  and socket adaptors  104  are respectively electrically coupled to each other via wires disposed within a housing  106 . The wires pass through elongate apertures  202  formed in the housing  106 . Each elongate aperture  202  has a curved portion  204  with a right angle equal to ninety degrees. The elongate aperture  202  is formed by cross drilling two holes in the housing  106 . 
     The conventional RF connector  100  suffers from certain drawbacks. For example, the RF connector  100  is relatively expensive to fabricate, is not VITA compliant, has a relatively low density pin count in area  108  (e.g., &lt;8 socket adaptors in a given interface), and has a relatively low isolation between adjacent pin/socket adaptor connections (e.g., because the wires associated with the socket adaptors of a first row  110  are longer than the wires associated with the socket adaptors of a second row  112 , and therefore are not phase matched with each other). 
     Referring now to  FIGS. 3-4 , there are provided illustrations that are useful for understanding an interconnect device  300  of the present solution. The interconnect device  300  is shown in a solid state in  FIG. 3  and a transparent state in  FIG. 4 . The interconnect device  300  is VITA compliant (e.g., VITA 67.3 compliant). 
     The interconnect device  300  is shown in  FIGS. 3-4  as being coupled to a PCB  302  between other electronic components  406 ,  408 . The interconnect device  300  is sized and shaped to fit within a space  410  existing between electronic components  406 ,  408 . In some scenarios, the space has a length of one inch and a width/depth of three quarters of an inch. The present solution is not limited in this regard. 
     The PCB  302  includes circuitry. For example, the circuitry includes, but is not limited to, communication components for a radio such as an RF communication device or a Software Defined Radio (“SDR”). Radios, RF communication devices and SDRs are well known in the art, and therefore will not be described herein. The present solution is not limited in this regard. The interconnect device  300  can be used with any embedded computer system or other electronic system. 
     The interconnect device  300  provides a means to connect the circuitry of the PCB  302  to an external device. In this regard, the interconnect device  300  comprises socket adaptors  304 ,  404  and wires  402 . The wires  402  are disposed in a housing  306  so as to electrically connect first socket adaptors  304  to second socket adaptors  404 , respectively. More detailed illustrations of the interconnect device  300  are provided in  FIGS. 5-11 . 
     Referring now to  FIG. 5 , there is provided a bottom perspective view of the interconnect device  300 . A top perspective view of the interconnect device  300  is provided in  FIG. 6 . As shown in  FIGS. 5-6 , the first and second socket adaptors  304 ,  404  include SMPM bullet adaptors. SMPM bullet adaptors are well known in the art, and therefore will not be described herein. Any known SMPM bullet adaptor can be used here. The present solution is not limited in this regard. Other types of socket adaptors can be used with the present solution in accordance with a given application. 
     The socket adaptors  304 ,  404  are at least partially inserted into the housing  306 . Ten socket adaptors  304  and ten socket adaptors  404  are shown in  FIGS. 5-6 . The present solution is not limited in this regard. Any number of socket adaptors can be provided in accordance with a given application. For example, in other scenarios, four or six socket adaptors  306 ,  404  are provided rather then ten. Still, it should be understood that the present solution allows for a high density of electrical connectors (e.g., 10) in given area (e.g., 1 inch by 1 inch area). 
     The housing  306  is a 3D printed part formed of a conductive material. The conductive material can include, but is not limited to, aluminum. The housing  306  has a generally L-shape. In this regard, the housing  306  comprises a first portion  502  that extends in a first direction perpendicular to a second direction in which a second portion  504  of the housing extends. First socket adaptors  304  are located in the first portion  502  of the housing  306 , while second socket adaptors  404  are located in the second portion  504  of the housing  306 . 
     The first socket adaptors  304  are arranged in a two dimensional grid pattern (e.g., an x-y grid pattern). The two dimensional grid pattern is defined by first and second rows  506 ,  508  of socket adaptors. The socket adaptors in each row  506 ,  508  are equally spaced apart from each other in a horizontal direction. However, the socket adaptors of the first row  506  are offset from the socket adaptors in the second row  508 . As such, a center axis  506  of a socket adaptor in the first row  506  is offset horizontally from a center axis  512  of a corresponding socket adaptor in the second row  508 . 
     The first socket adaptors  304  are shown as being of the same type. The present solution is not limited in this regard. Two or more of the first socket adaptors can alternatively be of different types selected in accordance with a given application. Still, it should be understood that in some applications it is undesirable to have flexible cable connectors. In this case, the interconnect device  300  is absent of flexible cable connectors (e.g., as shown in  FIGS. 3-6 ). 
     In some scenarios, the spacing between adjacent socket adaptors is maximized in the given interface area defined by a surface  514  of the housing  306 . This spacing maximization facilitates a high isolation between electrical connectors or connections. 
     Like to the first socket adaptors  304 , the second socket adaptors  404  are arranged in a two dimensional grid pattern (e.g., an x-y grid pattern). The two dimensional grid pattern is defined by first and second rows  606 ,  608  of socket adaptors. The socket adaptors in each row  606 ,  608  are equally spaced apart from each other in a horizontal direction. However, the socket adaptors of the first row  606  are offset from the socket adaptors in the second row  608 . As such, a center axis  606  of a socket adaptor in the first row  606  is offset horizontally from a center axis  612  of a corresponding socket adaptor in the second row  608 . 
     The second socket adaptors  404  are shown as being of the same type. This feature of the present solution ensures that the interconnect device  300  can be used with a single PCB (instead of with two or more PCBs as is required for some conventional RF connectors). The present solution is not limited in this regard. Two or more of the second socket adaptors can alternatively be of different types selected in accordance with a given application. 
     In some scenarios, the spacing between adjacent socket adaptors is maximized in the given interface area defined by a surface  614  of the housing  306 . This spacing maximization facilitates a high isolation between electrical connectors or connections. 
     Referring now to  FIG. 7 , there is provided an illustration of the interconnect device  300 . Internal elongate apertures  700 ,  702  are formed in the housing for receiving the wires  402 . The housing  306  is shown in a transparent or semi-transparent state so as to allow the internal elongate apertures  700 ,  702  to be visible. Notably, the apertures  700 ,  702  are designed such that the wires inserted therein have the same lengths. This design feature facilitates phase matching between sets of two socket adaptors and one wire. The present solution is not limited in this regard. The apertures  700 ,  702  can alternatively be designed so that the wires inserted therein have different lengths in accordance with a particular application. The apertures  700 ,  702  will be discussed in more detail below. 
     Referring now to  FIGS. 8-9 , there are provided illustrations that are useful for understanding the interconnect device  300 . In these drawings, the housing  306  is also shown in a semi-transparent state. A portion of the housing  306  has been cut away so that the internal structure and architecture for a set of two socket adaptors  304   1 ,  404   1  and a wire  402   1  can be seen more clearly. 
     The socket adaptors  304   1 ,  404   1  are electrically connected to each other via the wire  402   1 . The socket adaptors  304   1 ,  404   1  are arranged such that their center axis  804 ,  806  are perpendicular to each other. The wire  402   1  includes a center conductive core  800  covered by an outer dielectric material  802 . In some scenarios, wire  402   1  comprises a micro coaxial cable with an outer jacket and shield removed therefrom. Ends  900 ,  902  of the conductive core  800  are exposed such that an electrical connection between the conductive core  800  and socket adaptors  304   1 ,  404   1  can be established as shown in  FIGS. 8-9 . 
     During fabrication of the interconnect device  300 , socket adaptor  404   1  is inserted into a cavity  906  of the housing  306  until it is engages a wall  908  of the cavity  906 . The cavity  906  is sized and shaped so that the socket adaptor  404   1  is secured and retained therein once fully inserted into the housing  306 . The securement and retention is at least partially achieved through a frictional engagement between the adaptor  404   1  and a sidewall  910  of the cavity  906 . The present solution is not limited in this regard. Other securement and retention techniques can be used herein. For example, the securement and retention can be alternatively or additionally facilitated via a press-fit, a snap-fit, and/or an adhesive. 
     Next, the wire is inserted into a cavity  904  and through the aperture  700  until the end  900  of the center conductive core  800  is fully inserted into an aperture  912  of the socket adaptor  404   1 . Notably, a retention mechanism is provided to facilitate the retention of the wire  402   1  in the aperture  700 . 
     In some scenarios, the retention mechanism is provided as a part of the wire  402   1 . For example, the outer dielectric material  802  of the wire  402   1  has at least one end portion  914 ,  916  with a diameter greater than the diameter of a center portion  918 . The diameter(s) of end portion(s)  914 ,  916  is(are) selected to be the same as or slightly larger than the diameter of the aperture  912  such that a frictional engagement therebetween is established and maintained through use of the interconnect device  300 . 
     In other scenarios, the retention mechanism is provided as a separate component from the wire  402   1 . For example, spacers (not shown) are used to retain the wire  402   1  in a position relative to the aperture  700 . The spacers include a resilient member (e.g., a rubber ring) with a hole formed therein through which the end  900  of the center conductive core  800  and/or end of the outer dielectric material  1104  is inserted. The spacers are designed to have the same or slightly larger diameter (when not in use) than the diameter of the aperture  700  such that a frictional engagement therebetween is established and maintained through use of the interconnect device  300 . The spacers can be placed at any location along the elongate length of the aperture  700  and/or wire  402   1 . 
     Once the wire  404   1  is fully inserted into the aperture  700 , the socket adaptor  304   1  is then inserted into the cavity  904 , whereby an electrical connection is established between the center conductive core  800  and the socket adaptor  304   1 . The socket adaptor  304   1  is secured and retained in the cavity  904  in the same or similar manner as described above in relation to socket adaptor  404   1 . 
     Notably, aperture  700  is formed during the 3D printing of the housing  306 , rather than being machined or drilled as is done during fabrication of conventional interconnect devices. As such, aperture  700  does not comprise two straight cross-drilled holes having a right angle (i.e., ninety degrees) relative to each other. Instead, aperture  700  has one or more bends  920 ,  922  with bend angles less than ninety degrees. The bend angles of bends  920 ,  922  can be the same or different from each other. 
     This is an important feature of the present solution since it allows for phase matching between connectors (or sets of two socket adaptors and one wire). The phase matching is achieved by providing apertures  700 ,  702  with the same lengths. In order to provide same length apertures, the bend angles of bends  920 ,  922  of aperture  700  are greater than the bend angles of bends  924 ,  926  of aperture  702 , respectively. The present solution is not limited in this regard since phase matching may not be desirable in certain applications. In this regard, it should be understood that the apertures  700 ,  702  can alternatively have different lengths and/or the bend angles of bends  920 - 926  can be the same or different from each other. 
     The radius of each bend  920 - 922  is selected so that the wires  402   1 ,  402   2  can be inserted into the apertures  700 ,  702 . The present solution is not limited in this regard. 
     As shown in  FIG. 9 , the first portion  502  of the housing  306  extends in a first direction  930  perpendicular to a second direction  932  in which a second portion  504  of the housing  306  extends. The first portion  502  has a height  934 , a width  938  and a length (not shown). The second portion  504  has a height  936 , a width  940 , and a length (not shown). These dimensions are selected in accordance with a particular application. For example, these dimensions are selected so that the interconnect device  300  fits within the space  410  existing between electronic components  406 ,  408 , as shown in  FIGS. 3-4 . The present solution is not limited in this regard. 
     Referring now to  FIGS. 10-11 , there are provided illustrations that are useful for understanding the interconnect device  300 . In these drawings, the housing  306  is also shown in a semi-transparent state. A portion of the housing  306  has been cut away so that the internal structure and architecture for a set of two socket adaptors  304   2 ,  404   2  and a wire  402   2  can be seen more clearly. 
     The socket adaptors  304   2 ,  404   2  are electrically connected to each other via the wire  402   2 . The socket adaptors  304   2 ,  404   2  are arranged such that their center axis  1004 ,  1006  are perpendicular to each other. The wire  402   2  includes a center conductive core  1102  covered by an outer dielectric material  1104 . In some scenarios, wire  402   2  comprises a micro coaxial cable with an outer jacket and shield removed therefrom. Ends  1106 ,  1108  of the conductive core  1102  are exposed such that an electrical connection between the conductive core  1102  and socket adaptors  304   2 ,  404   2  can be established as shown in  FIGS. 10-11 . 
     During fabrication of the interconnect device  300 , socket adaptor  404   2  is inserted into a cavity  1114  of the housing  306  until it is engages a wall  1112  of the cavity  1114 . The cavity  1114  is sized and shaped so that the socket adaptor  404   2  is secured and retained therein once fully inserted into the housing  306 . The securement and retention is at least partially achieved through a frictional engagement between the adaptor  404   2  and a sidewall  1112  of the cavity  1114 . The present solution is not limited in this regard. Other securement and retention techniques can be used herein. For example, the securement and retention can be alternatively or additionally facilitated via a press-fit, a snap-fit, and/or an adhesive. 
     Next, the wire  402   2  is inserted into a cavity  1110  and through the aperture  702  until the end  1108  of the center conductive core  1102  is fully inserted into an aperture  1116  of the socket adaptor  404   2 . Notably, a retention mechanism is provided to facilitate the retention of the wire  402   2  in the aperture  702 . 
     In some scenarios, the retention mechanism is provided as a part of the wire  402   2 . For example, the outer dielectric material  1104  of the wire  402   2  can have at least one end portion  1118 ,  1120  with a diameter greater than the diameter of a center portion  1122 . The diameter(s) of end portion(s)  1118 ,  1120  is(are) selected to be the same as or slightly larger than the diameter of the aperture  702  such that a frictional engagement therebetween is established and maintained through use of the interconnect device  300 . 
     In other scenarios, the retention mechanism is provided as a separate component from the wire  402   2 . For example, spacers (not shown) are used to retain the wire  402   2  in a position relative to the aperture  702 . The spacers include a resilient member (e.g., a rubber ring) with a hole formed therein through which the end of the center conductive core  1102  and/or end of the outer dielectric material  1104  is inserted. The spacers are designed to have the same or slightly larger diameter (when not in use) than the diameter of the aperture  702  such that a frictional engagement therebetween is established and maintained through use of the interconnect device  300 . The spacers can be placed at any location along the elongate length of the aperture  702  and/or wire  402   2 . 
     Once the wire  402   2  is fully inserted into the aperture  702 , the socket adaptor  304   2  is then inserted into the cavity  1110 , whereby an electrical connection is established between the center conductive core  1102  and the socket adaptor  304   2 . The socket adaptor  304   2  is secured and retained in the cavity  1110  in the same or similar manner as described above in relation to socket adaptor  404   2 . 
     Notably, aperture  702  is formed during the 3D printing of the housing  306 , rather than being machined or drilled as is done during fabrication of conventional interconnect devices. As such, aperture  702  does not comprise two straight cross-drilled holes having a right angle (i.e., ninety degrees) relative to each other. Instead, aperture  702  has one or more bends  1124 ,  1126  with bend angles less than ninety degrees. The bend angles of bends  1124 ,  1126  can be the same or different from each other. 
     Referring now to  FIG. 13 , there is provided a flow diagram of an illustrative method  1300  for making an interconnect device for electronic circuits. The interconnect device is VITA compliant and the electronic circuits comprise radio circuitry. The method  1300  begins with  1302  and continues with  1304  where a housing is fabricated as a single 3D printed part having a plurality of apertures with bend angles less than ninety degrees. Next in  1306 , wires are inserted into the plurality of apertures of the housing. In  1308 , electrical connections are respectively established between (A) the wires and a plurality of first socket adaptors and (B) the wires and a plurality of second socket adaptors. 
     In some scenarios, the apertures are designed such that the wires inserted therein all have a same length. Accordingly, phase matching is provided between sets of a first socket adaptor, a second socket adaptor and a wire. 
     In those or other scenarios, the first socket adaptors are of a same type as the plurality of second socket adaptors. A center axis of each first socket adaptor is perpendicular to a center axis of each second socket adaptor. At least one of the first socket adaptors and the second socket adaptors are arranged as a two dimensional grid of socket adaptors in a given area of the housing. A spacing between adjacent ones of the first socket adaptors and a spacing between adjacent ones of the second adaptors are selected to provide an optimized isolation between sets of first socket adaptors, second socket adaptors and wires. 
     In those or yet other scenarios, each wire comprises at least one end portion with a first diameter greater than a second diameter of center portion thereof. The end portion engages a sidewall of a respective aperture so that the wire maintains a certain position relative to respective first and second socket adaptors throughout use of the interconnect device. 
     Although the present solution has been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature of the present solution may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the present solution should not be limited by any of the above described embodiments. Rather, the scope of the present solution should be defined in accordance with the following claims and their equivalents.