Cable Connection Structure With Bent Inner Conductor

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing cable connection structure over a ground terminal is prone to damage of the inner conductor of the coaxial cable due to tensile and compressive stresses caused by temperature changes, as the inner insulator and heat-shrinkable tube expand and contract.

Innovation Solution

A cable connection structure with a bent portion formed on the inner conductor of the coaxial cable, which is exposed between the crimp terminal and the end of the inner insulator, allows for displacement of the insulator and heat-shrinkable tube, thereby restraining stresses from acting on the inner conductor, and maintaining a sufficient distance from the ground terminal to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the inner insulator and heat-shrinkable tube are expanded and contracted due to temperature changes, then the cable connection structure adapts to thermal expansion, but tensile and compressive stresses act on the inner conductor causing damage

Engineering Contradiction:

Improvethermal adaptationVSAvoidinner conductor integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

A curved portion is formed at a specific position of the inner conductor within the heat-shrinkable tube. This curvature allows the inner conductor to flex and absorb thermal expansion and contraction forces, preventing direct stress transmission that would cause damage while maintaining electrical connectivity and structural integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Reliability

If the inner conductor is exposed between the crimp terminal and the end of the inner insulator, then electrical connection is achieved, but the inner conductor is vulnerable to stress damage from insulator expansion and contraction

Engineering Contradiction:

Improveelectrical connectionVSAvoidstress damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The curved portion is strategically positioned at the exposed section of the inner conductor between the crimp terminal and the inner insulator end. This curvature transforms the vulnerable straight conductor into a flexible element that can bend to accommodate thermal movements, thereby protecting the electrical connection from stress-induced damage.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The curved portion acts as a pre-formed buffer zone that anticipates and absorbs thermal stresses before they can reach the critical connection points. This preemptive design feature cushions the inner conductor against future thermal cycling damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 bent portion of the inner conductor within the heat-shrinkable tube absorbs the expansion and contraction, preventing stress-induced damage and ensuring consistent cable characteristics by maintaining the necessary distance from the ground terminal.

Implementation Method 1

an insulative heat-shrinkable tube that covers the coaxial cable, the cable, and the crimp terminal

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

the inner insulator and heat-shrinkable tube expand and contract

Methodology Applied

Scientific EffectThermal expansion and contraction: Thermal Expansion

Implementation Method 3

the bent portion of the inner conductor within the heat-shrinkable tube absorbs the expansion and contraction, preventing stress-induced damage

Methodology Applied

Scientific EffectStress absorption: Stress Relaxation

Data Source

PatentUS7901246B2Cable connection structure

Publication Date: 2011.03.08 YAZAKI CORP

AI summary

A cable connection structure includes a coaxial cable that includes an inner conductor, an inner insulator covering the inner conductor, a braided wire covering the inner insulator, and a sheath covering the braided wire, a cable that includes a core wire and a sheath covering the core wire, and is arranged in series with the coaxial cable, a ground terminal that connects the braided wire to a ground, and fixes the coaxial cable and the cable, a crimp terminal that press-clamps the inner conductor of the coaxial cable and the core wire of the cable to electrically connect to each other, and an insulative heat-shrinkable tube that covers the coaxial cable, the cable, and the crimp terminal. The inner conductor, exposed from the inner insulator and arranged between the crimp terminal and an end portion of the inner insulator of the coaxial cable in the heat-shrinkable tube, has a bent portion.