Cable Connector Assembly With External Braid Fixing
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Solution Overview
Problem
Existing linear cable connectors are complex, costly, and difficult to assemble, particularly in outdoor high-voltage environments, where the large number of components and intricate assembly processes cause inconvenience, and the braid of the cable assembly often leads to short circuits due to debris entering screw holes.
Innovation Solution
A cable connector assembly comprising a cable connection module with a guiding member for smooth insertion of the inner conductor and a shell module with a metal ring to fix the braid outside, reducing component count and simplifying assembly, while preventing braid debris from entering screw holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable connector designs are used, then electrical connection is achieved, but the number of components increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple functional components into integrated structures. The insulation housing integrates the guiding member, positioning structures, and sealing features into a single unified component. The shell module combines the metal shell, insulation ring, and sealing elements into an integrated assembly, reducing the total number of separate parts while maintaining reliable electrical connection and mechanical stability.
Solution Approach 2:
The insulation housing serves multiple functions simultaneously: it guides the inner conductor through its guiding member, provides electrical insulation, positions the braid through integrated positioning structures, and seals the connection interface. The shell module provides both mechanical protection and electrical shielding while facilitating assembly through its integrated design.
2Reliability
If traditional cable connector designs are used, then electrical connection is achieved, but assembly process becomes complex and time-consuming
Solution Approach 1:
The guiding member is pre-formed with a tapered surface and integrated positioning structures that automatically guide the inner conductor and braid into correct positions during insertion. The shell module is pre-assembled with the insulation ring and sealing elements positioned, allowing for rapid installation without requiring multiple separate assembly steps.
Solution Approach 2:
The guiding member features a tapered surface that dynamically adapts to the inner conductor during insertion, providing progressive guidance and self-alignment. The slidable fit between the insulation housing and shell module allows dynamic adjustment during assembly, facilitating smooth insertion and automatic positioning without requiring precise manual alignment.
3Device complexity
If braid is not properly positioned, then assembly is simpler, but braid debris enters screw hole causing short circuit
Solution Approach 1:
The insulation housing acts as an intermediary structure that captures and contains the braid through integrated positioning structures. The guiding member with its tapered surface and positioning features serves as a mediator that guides the braid away from the screw hole area, preventing debris from entering the fastening interface while maintaining assembly simplicity.
Solution Approach 2:
The braid positioning function is extracted and integrated into the guiding member and insulation housing structure. The positioning structures physically separate the braid from the screw hole area, removing the hazard of braid debris entering the fastening interface while keeping the overall assembly process simple and straightforward.
4Ease of operation
If inner conductor insertion is difficult, then more components are needed for guidance, but this increases device complexity
Solution Approach 1:
The guiding member features a tapered surface with curved geometry that smoothly receives and guides the inner conductor during insertion. The conical shape provides progressive alignment and reduces friction, enabling easy insertion without requiring additional complex guidance mechanisms or multiple components.
Data Source
AI summary
A cable connector assembly comprises a cable connection module and a shell module connectable thereto. The cable connection module includes a center conductor, a first insulation housing in which the center conductor is disposed, and a second insulation housing slidably fitted around the first insulation housing. The first insulation housing includes a guiding member sized to slidably guide an inner conductor of a cable assembly therethrough and into the center conductor. The shell module includes a metal shell connectable with the second insulation member. The cable connection module and the shell module are adapted such that, when the cable connection module and the shell module are assembled together with the cable assembly, a braid of the cable assembly fitted around the inner conductor of the cable assembly is fixed outside of the first insulation housing.