1.85mm connectors Design and Structure
Sep 29, 2024|
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The 1.85mm connector stands out due to its precise engineering and robust design, which enables it to perform efficiently in high-frequency environments. Its physical structure is similar to the 2.4mm connector, but the reduced size of the outer conductor and air dielectric interface improves its performance, making it suitable for applications requiring frequencies up to 65 GHz.
Components Breakdown
Outer Conductor: The outer conductor of the 1.85mm connector serves as a shield that prevents external electromagnetic interference (EMI) from affecting the signal transmitted through the inner conductor. It also provides the necessary grounding for the signal. The 1.85mm outer conductor is designed with high precision to ensure proper mating and a tight fit, which minimizes reflections and losses at high frequencies.
Inner Conductor: The inner conductor, often made from high-quality metals such as copper or gold-plated materials, is responsible for carrying the RF signal. The diameter of the inner conductor is carefully designed to support high-frequency signals without causing significant attenuation. The small size of the 1.85mm connector’s inner conductor allows it to maintain signal integrity, even in extremely high-frequency applications.
Dielectric Spacer: The air dielectric in the 1.85mm connector minimizes signal loss, as air has very low dielectric constant compared to other materials. The air dielectric is supported by precision alignment of the inner and outer conductors, which reduces capacitance and ensures optimal transmission characteristics across the entire frequency range.
Coupling Mechanism: The 1.85mm connector features a threaded coupling mechanism that ensures a secure and stable connection. The precision threads provide strong mechanical support, preventing any unintended disconnections during operation. This mechanism also enhances the connector’s resistance to vibrations, making it ideal for use in environments that require rugged durability, such as aerospace and defense.
Mating Interface: The mating interface is designed to provide an exact fit between the male and female connectors, minimizing air gaps or misalignments that could degrade performance. The interface includes an alignment feature to ensure that the connectors mate without damaging the delicate inner conductors. This precision is critical in maintaining low insertion loss and high return loss, both essential factors in high-frequency applications.
Materials and Durability
The materials used in 1.85mm connectors are selected for both electrical performance and long-term durability. Common materials include:
Body Material: Stainless steel is often used for the connector’s body due to its strength and resistance to corrosion. In high-performance applications, stainless steel offers the durability necessary for repeated use in harsh environments.
Plating: Connectors are typically plated with materials such as gold or silver to enhance conductivity and prevent corrosion. Gold plating is especially common for the inner conductors because it offers excellent conductivity and protection against oxidation.
Insulation: The air dielectric is supported by minimal use of insulating materials. However, for mechanical integrity and protection, PTFE (polytetrafluoroethylene) or other low-loss materials may be used in small quantities. These materials ensure high-temperature stability and low signal loss.
Precision Engineering
Each component of the 1.85mm connector is engineered with micron-level precision. This meticulous manufacturing process is critical to ensure that the connector operates reliably at very high frequencies, where even small imperfections could significantly degrade performance. The alignment of the inner and outer conductors, the tight tolerances of the threaded coupling, and the careful selection of materials all contribute to the connector’s ability to maintain high signal integrity.
Connector Variants
There are different types of 1.85mm connectors available, depending on the specific application and mechanical requirements. Common variants include:
Straight connectors: These are the most common type and are used in standard RF and microwave systems where space constraints are not a concern.
Right-angle connectors: These connectors are designed for applications where space is limited, and a straight connector cannot be used. They offer flexibility in system design by allowing connections at a 90-degree angle.
Bulkhead connectors: Designed to be mounted on a panel or enclosure, bulkhead connectors provide a secure and stable connection through a fixed surface, often used in test and measurement setups.
