Cable Connector Shielding Design for Loosening Resistance

Solution Overview

Problem

Cable connectors with soldered caulking sections face increased machining costs and quality variations, and are prone to loosening, which destabilizes conduction and reduces fixing strength.

Innovation Solution

A cable connector design featuring a conductive shell with a caulking section caulked to the insulating part, accompanied by a cylindrical sleeve over the caulking section, which suppresses loosening forces and maintains conduction stability while preventing a decrease in fixing strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a cable connector uses a thick and elastic cable jacket with caulking, then the connector can be assembled easily, but the caulking loosens under load and conduction becomes unstable

Engineering Contradiction:

Improveease of assemblyVSAvoidconduction stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The connector is divided into multiple functional segments: a flexible support member that provides elastic support, a rigid barrel that maintains structural integrity, and a shield that provides electrical conduction. This segmentation allows each component to perform its specific function optimally without compromising overall reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector combines materials with different properties: the flexible support member uses elastic material to accommodate cable movement, while the barrel uses rigid material for structural stability. This composite approach ensures both ease of assembly and reliable conduction under load.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a cable connector uses a soldered caulking section to prevent loosening, then conduction stability improves, but machining cost increases and quality variations occur

Engineering Contradiction:

Improveconduction stabilityVSAvoidmachining cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the soldering process with a mechanical interference fit between the shield and the barrel. The shield is directly received by the barrel with tight tolerances, eliminating the need for soldering while maintaining conduction stability. This substitution reduces machining complexity and quality variations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a cable connector uses a soldered caulking section to prevent loosening, then conduction stability improves, but machining cost increases

Engineering Contradiction:

Improveconduction stabilityVSAvoidmachining cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the soldering process with a mechanical interference fit between the shield and the barrel. The shield is directly received by the barrel with tight tolerances, eliminating the need for soldering while maintaining conduction stability. This substitution reduces machining complexity and quality variations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If a cable connector uses conventional caulking without additional support, then the structure remains simple, but fixing strength decreases under load

Engineering Contradiction:

Improvestructural simplicityVSAvoidfixing strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The connector is divided into multiple functional segments: a flexible support member that provides elastic support, a rigid barrel that maintains structural integrity, and a shield that provides electrical conduction. This segmentation allows each component to perform its specific function optimally without compromising overall reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible support member acts as a counterbalancing element that compensates for loosening forces. When load is applied, the support member deforms elastically to maintain constant contact pressure between the cable jacket and the barrel, preventing fixation strength degradation.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

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 design effectively suppresses machining cost increases and quality variations, stabilizes conduction with the cable's conductive parts, and maintains the fixing strength by preventing caulking loosening and ensuring consistent electrical contact.

Implementation Method 1

If a force in a direction of loosening the caulking of the caulking section is applied from the insulating part of the cable etc., the cylindrical first sleeve suppresses the force in the direction of loosening the caulking of the caulking section.

Methodology Applied

Scientific EffectMechanical Force: Force

Data Source

PatentUS11646524B2Cable connector and method for manufacturing cable connector

Publication Date: 2023.05.09 SMK CO LTD

AI summary

A cable connector can suppress an increase in machining cost and restrict variations in quality while preventing loosening of the caulking, stabilizing conduction with a conductive part of the cable, and preventing a decrease in the fixing strength to the cable. A cable connector includes a conductive contact that is connected to an internal conductive part; an insulating insulator that holds the contact; a conductive shell that includes a caulking section caulked to an external insulating part and covers the insulator; and a cylindrical conductive outer sleeve that is located over the caulking section and caulked to the external insulating part via the caulking section.