Cable Connector Heat-Resistant Insulation for Soldering
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Solution Overview
Problem
Existing cable connector assemblies can damage adjacent single wires during soldering due to the outer insulative layers being compromised when connecting coaxial wires.
Innovation Solution
Incorporating a heat-resistant first insulative layer for single wires adjacent to coaxial wires, which is further enclosed by a second insulative layer, specifically made of materials like PTFE and PET, to prevent damage during soldering of the metal braided layer of coaxial wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If outer insulative layers of adjacent single wires are used during soldering of coaxial wires, then soldering can be performed, but the outer insulative layers get damaged causing wire damage
Solution Approach 1:
The patent applies preliminary action by pre-arranging the soldering sequence: single wires are soldered to their pads first, then the coaxial wires are soldered afterward. This sequential arrangement prevents the outer insulative layers of single wires from being damaged during coaxial wire soldering, as the single wires are already secured and protected by their insulative layers when the heat-generating coaxial soldering occurs.
2Area of stationary object
If coaxial wires and single wires are arranged adjacent to each other in a row, then space is utilized efficiently, but heat from soldering coaxial wires damages adjacent single wires
Solution Approach 1:
The patent implements preliminary action by establishing a predetermined soldering sequence where single wires are soldered before coaxial wires. This allows efficient spatial arrangement of wires adjacent to each other on the PCB while preventing heat damage through proper sequencing - the single wires are already in place and protected when the heat-intensive coaxial wire soldering is performed.
3Ease of manufacture
If outer insulative layers of single wires are damaged during soldering, then wire protection is compromised, but short circuits may occur
Solution Approach 1:
The patent applies preliminary action by soldering single wires to their respective pads before soldering coaxial wires. This sequence ensures that the outer insulative layers of single wires remain intact throughout the coaxial wire soldering process, preventing exposed conductors that could cause short circuits while still allowing proper soldering connectivity.
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
Effectively prevents damage to single wires during soldering, ensuring reliable electrical connections and preventing short circuits, while maintaining the structural integrity of the cable connector assembly.
Implementation Method 1
The first insulative layer is made of heat-resisting material to prevent the adjacent single wires from being damaged when soldering the metal braided layer of the coaxial wires
Data Source
AI summary
A cable connector assembly includes a PCB defining some second conductive pads disposed on a rear end portion of the PCB and some third conductive pads disposed behind the second conductive pads, a cable defining a number of coaxial wires and single wires, and a housing. Each coaxial wire has a first inner conductor, an inner insulative layer enclosing the first inner conductor, a metal braided layer soldered to the corresponding third conductive pads, and an outer insulative layer. Part of the coaxial wires and single wires adjacent to the coaxial wires are disposed on at least one surface of the PCB. Each single wire has a second conductor, a first insulative layer, and a second insulative layer. The first insulative layer is made of heat-resisting material to prevent the adjacent single wires from being damaged when soldering the metal braided layer of the coaxial wires.