Crimpable Bridge Contact for Twinax Cable Impedance Matching
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Solution Overview
Problem
Existing cable repair methods fail to maintain the correct length difference between wires of a twinaxial/differential pair cable, leading to signal integrity issues and impedance mismatches, especially in high-speed data transmission systems.
Innovation Solution
A crimpable bridge contact with symmetrical elongated terminal portions and tool alignment features ensures precise crimping and connection of cable ends, maintaining wire length equality and impedance matching, while allowing for detachable tool alignment portions for ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable repair methods are used, then cable replacement is required, but this increases loss of time and productivity
Solution Approach 1:
The bridge contact is divided into multiple terminal portions (first terminal portion, second terminal portion, etc.) that can independently connect to different cable ends. This segmentation allows the repair kit to join separate cable sections without replacing the entire cable, significantly reducing repair time while maintaining functionality.
Solution Approach 2:
The bridge contact serves as an intermediary component that connects two separate cable ends together. Instead of replacing the entire cable, the bridge contact mediates the connection between the first cable end and second cable end, enabling quick repair while maintaining signal integrity through proper impedance matching.
2Ease of operation
If cable length is adjusted during repair, then connection flexibility is improved, but signal integrity and impedance matching deteriorate
Solution Approach 1:
The bridge contact is pre-configured with specific terminal portions (first terminal portion, second terminal portion, third terminal portion) that are designed to maintain correct wire length differences. This preliminary design ensures that when cables are connected through the bridge contact, the impedance matching and signal integrity are preserved without requiring precise field adjustments.
Solution Approach 2:
The bridge contact is designed with specific geometric parameters and terminal configurations that control the electrical characteristics. By carefully designing the terminal portions and their arrangements, the bridge contact maintains the correct length difference between wires, thereby controlling impedance and signal integrity parameters while still allowing connection flexibility.
3Ease of operation
If tool alignment features are made detachable, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The tool alignment portions are segmented as separate, detachable components from the main bridge contact body. These alignment portions can be removed after use, transforming the bridge contact from a complex integrated structure into a simpler final product. This segmentation improves ease of operation during installation while the removed portions eliminate post-installation complexity.
Solution Approach 2:
The tool alignment portions are designed to be discarded after serving their temporary purpose during the crimping operation. Once the bridge contact is properly installed, the detachable alignment portions are removed and discarded, leaving behind a simple, clean connection without unnecessary components. This approach improves ease of operation during installation while eliminating device complexity in the final product.
Data Source
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Figure 6A~6B
AI summary
A cable repair set comprising a crimpable bridge contact, the bridge contact comprising at least one elongated terminal portion, each terminal portion comprising first and second crimp portions arranged in series, the crimp portions comprising crimping wings, two tool alignment portions, connected to the respective opposing ends of the elongated terminal portion, wherein each alignment portion comprises at least one tool alignment means.