Bundle Cable Connector Assembly Bird Cage Prevention
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Solution Overview
Problem
Conventional bundle cable connector assembly methods often result in issues like bird caging, stray wires, and dielectric shielding shrinkage, leading to potential short circuits and performance degradation.
Innovation Solution
A method involving wire stripping to create a bird cage preventative zone and an exposed tip, tinning, inserting the wire into a connector pin, crimping with heat to secure the pin, and mounting a wire-locking device to prevent loose connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional assembly steps are used to couple wire to connector pin, then assembly is simple, but bird caging and wire thread stretching occur
Solution Approach 1:
The wire is pre-tinned before insertion into the connector pin. This preliminary action of applying solder coating to the wire strands prevents them from separating and forming bird cages during the crimping process, while still allowing for simple assembly operations.
Solution Approach 2:
The invention changes the physical state of the wire by applying heat and solder material during the tinning process. This parameter change (from bare wire to tinned wire) fundamentally alters how the wire behaves during crimping, preventing bird caging while maintaining assembly simplicity.
2Device complexity
If conventional crimping is performed without heat, then process is simple, but dielectric shield shrinking and loose wire threads occur
Solution Approach 1:
The invention utilizes the phase transition of solder from solid to liquid state during heat application. The solder melts during crimping, flows into the connector pin, and then resolidifies to create a strong mechanical and electrical bond, preventing loose wire threads and improving connection reliability.
Solution Approach 2:
The invention replaces purely mechanical crimping with a thermally-assisted crimping process. By introducing heat and phase change of solder, the mechanical bonding process is enhanced to achieve more reliable connections without significantly increasing overall process complexity.
3Reliability
If wire is stripped completely to expose tip, then connection is secure, but bird caging occurs during assembly
Solution Approach 1:
By applying solder coating to the stripped wire strands, the physical parameters of the wire surface change. The tinned wire strands are held together by the solder, preventing them from splaying out and forming bird cages, while still allowing secure insertion into the connector pin.
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
This method effectively eliminates bird caging and dielectric shield shrinkage, ensuring reliable electrical connections and preventing short circuits by securely locking the wire within the connector assembly.
Implementation Method 1
crimping the pin to the wire at the crimping zone using heat so that the tinning solder melts
Data Source
AI summary
A method for assembling a bundle cable connector assembly that eliminates bird caging, wire threads extruding through a connector pin, loose wire threads, dielectric shield shrinking, etc. The method includes stripping the wire to create a birdcage preventative zone and an exposed tip with a crimping zone therebetween, and tinning the exposed wire at the birdcage preventative zone and the tip. The method then includes inserting the wire into a connector pin, and crimping the pin to the wire at the crimping zone using heat so that the tinning solder melts. The method then includes mounting the pin to a connector body and mounting a wire-locking device to the connector body to lock the pin to the connector body.