Angled Coaxial Connector Assembly Reducing Part Count
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Solution Overview
Problem
Existing connection assemblies for coaxial cables in the automobile market, particularly those conforming to FAKRA and USCAR standards, require a large number of parts and complex assembly processes, leading to high manufacturing costs and time-consuming operations.
Innovation Solution
An angled coaxial electrical connector assembly with a central contact that can be crimped onto a coaxial cable, featuring a U-shaped or V-shaped crimping portion and a bayonet connection, along with a sleeve and housing design that simplifies assembly and reduces part count, allowing for simultaneous crimping of the central conductor and shielding braid or insulating sheaths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional centering parts and attachment parts are used to enable rotation of the angled connector, then the connector can be mated with complementary connectors, but the number of parts increases and assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the centering function and attachment function into the single elbow sleeve component. The sleeve's internal geometry provides centering for the connector while its external features enable attachment to the housing, eliminating the need for separate centering parts and attachment parts. This merging reduces the total part count and simplifies assembly operations.
Solution Approach 2:
The elbow sleeve is designed as a multi-functional component that simultaneously performs centering, positioning, and attachment functions. The single component handles multiple tasks that would traditionally require separate parts, reducing complexity while maintaining the ability to mate with complementary connectors.
2Reliability
If multiple separate parts are used for the angled connector assembly, then each part can be optimized for its specific function, but the assembly process becomes time-consuming and manufacturing cost increases
Solution Approach 1:
The connector body and elbow sleeve are designed as integrated components where the sleeve is received within the housing and the connector is received within the sleeve. This nested integration reduces the number of separate assembly operations while maintaining functional optimization of each component.
Solution Approach 2:
The patent employs a nested structure where the elbow sleeve is received inside the housing and the coaxial connector is received inside the elbow sleeve. This nesting arrangement allows multiple functional components to be assembled in a compact, hierarchical manner that reduces assembly steps and improves manufacturing efficiency.
3Ease of manufacture
If clearance is provided on either side of the bearing portion of the insulating element, then the crimping tool can access the crimping portion, but the mechanical retention and electrical continuity are compromised
Solution Approach 1:
The patent resolves the accessibility conflict by changing the approach dimension. The crimping tool accesses the crimping portion from a direction that does not require lateral clearance, allowing the bearing portion to be flush with the insulating element face while maintaining both tool accessibility and structural integrity.
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
The solution reduces the complexity and cost of assembly by using fewer parts and enabling a simpler, quicker assembly process, while enhancing mechanical retention and electrical continuity, and reducing the risk of connector degradation.
Implementation Method 1
a central contact provided with at least one crimping portion which can be crimped with a central conductor of the coaxial cable
Implementation Method 2
The insulating element of the connector is advantageously configured so that the central contact of the connector is fixed to the latter by a bayonet connection
Data Source
Figure 1~3
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AI summary
The present invention relates to a connection assembly (1), characterized in that it comprises: - an angled coaxial electrical connector (2) intended to be mounted on a coaxial cable (3), the connector (2) comprising: - a central contact having at least one crimping portion that can be crimped with a central conductor of the coaxial cable, - an insulating element comprising a support portion having an upper face on which the crimping portion of the central contact is applied at least partially and, - a body receiving the insulating element, - a housing (4) hollowed internally and, - an angled sleeve (5), comprising a first tubular portion extending along a first axis of the sleeve and intended to be received inside the housing (4) and a second portion extending along a second axis of the sleeve and comprising a housing for receiving the coaxial connector (2) mounted on the coaxial cable (3).