Cable Connector Groove Design for Reliable Electrical Connection
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Solution Overview
Problem
Conventional methods for connecting a coaxial cable to a terminal often result in unreliable electrical connections due to gaps between components, cable disconnection, and increased manufacturing complexity and cost, particularly in methods involving soldering or piercing terminals.
Innovation Solution
A cable connector design featuring grooves on the cable's insulation layer for easy terminal piercing and a shield shell with locking pieces to secure the cable, preventing disconnection and ensuring stable electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect the inner conductor to the terminal, then reliable electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical connection method) with a mechanical pressing connection method. The terminal's pressing portion directly presses against the inner conductor to establish electrical connection, eliminating the need for soldering equipment and complex soldering procedures while maintaining reliable electrical connectivity.
Solution Approach 2:
The patent employs a simple pressing mechanism that can be easily manufactured and replaced, substituting for expensive and complex soldering equipment. The pressing connection structure is designed to be cost-effective and simple, reducing manufacturing investment and operational costs.
2Ease of manufacture
If press-contact method is used to connect the inner conductor to the terminal, then manufacturing process is simplified, but electrical connection reliability deteriorates due to gaps and cable movement
Solution Approach 1:
The patent applies local quality by creating a groove at the specific location where the inner conductor contacts the terminal's pressing portion. This groove structure locally enhances the connection by preventing gap formation and cable movement at the critical contact point, while the rest of the structure maintains its simple pressed design. The groove ensures consistent electrical contact without complicating the overall manufacturing process.
3Reliability
If piercing terminal is used to connect the cable to the terminal, then direct electrical connection is achieved, but terminal damage occurs when piercing force is too strong
Solution Approach 1:
The patent applies preliminary action by pre-forming a groove in the cable insulation at the exact location where the terminal needs to contact the inner conductor. This groove is created before the terminal pressing operation, so when the terminal is pressed, it simply follows the pre-prepared path to reach the inner conductor without needing to exert excessive piercing force, thereby avoiding terminal damage.
Solution Approach 2:
The groove acts as an intermediary structure that facilitates the connection between the terminal and inner conductor. Instead of the terminal directly piercing through the insulation (which requires high force), the groove provides a pre-formed channel that guides the terminal's pressing portion to the inner conductor, reducing the required force and preventing terminal damage.
Data Source
AI summary
A cable connector and a manufacturing method thereof. The method includes: providing an insulation body, putting a terminal that has a receiving portion into the insulation body, preparing at least one groove on a cable, in which the cable has a first part inserted in the insulation body and a second part extending out of the insulation body, and the groove is provided on the first part, pressing the cable, so that a side edge of the receiving portion pierces the cable at the groove, thereby electrically connecting the terminal and an inner conductor of the cable. The groove enables the terminal to pierce the cable easily, implementing desirable electrical connection between the inner conductor and the terminal, and also stops the cable in the extending direction of the cable, preventing the cable from escaping.