Cable Connector Assembly With Exposed Weld Zone for Signal Integrity
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Solution Overview
Problem
Existing cable connector technologies face challenges in maintaining signal integrity due to impedance decreases and cable attenuation caused by internal injection molding, while lacking stability and reliability without it.
Innovation Solution
A cable connector design featuring a plastic main body with a cavity, a contact body, and a cable, where a rubber strip is injection-molded to fill assembly gaps between components, and a cable fixing piece is injection-molded to secure the cable, preventing movement and improving connection strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If internal injection molding is used to fill gaps between components, then connection strength and stability are improved, but impedance decreases and cable attenuation increases at welding spots
Solution Approach 1:
The patent extracts the injection molding process from the welding spot area by designing a dedicated cable fixing piece with a separate injection molding cavity. This allows the rubber strip to be injection-molded into gaps between components without encroaching on the cable welding spots, thereby maintaining both connection strength and signal integrity
Solution Approach 2:
The patent segments the connector into distinct functional zones: a cable fixing piece for mechanical attachment, a contact body for electrical connection, and a plastic main body for structural support. This segmentation allows the rubber strip to be applied selectively to gap areas without affecting the cable welding spots
2Stability of the object's composition
If internal injection molding is used to secure components, then stability against shaking and movement is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the molding structure into two independent parts: a cable fixing piece with its own injection molding cavity for securing the cable, and a separate rubber strip injection molding groove for filling gaps. This segmentation simplifies the overall molding process compared to a single complex internal molding system
Solution Approach 2:
The patent introduces a rubber strip as an intermediary material that is injection-molded into gaps between components. This rubber strip acts as a mediator that provides stability and shock absorption without requiring complex internal molding structures, thereby reducing manufacturing complexity while maintaining component stability
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 enhances signal integrity by avoiding impedance reduction at welding spots, stabilizes the connection, and improves reliability by preventing component shaking, thus ensuring a robust and reliable cable connector assembly.
Implementation Method 1
A rubber strip is injection-molded in the injection-moulding groove, and is configured to fill an assembling gap between the cover body and the inner wall of the cavity
Implementation Method 2
a cable fixing piece is injection-molded to secure the cable
Data Source
AI summary
A cable connector and a connector assembly including the cable connector are provided. The cable connector includes a plastic main body, a contact body and a cable. A cavity is formed in the plastic main body. The contact body is fixed on the plastic main body and extends into the cavity. The cable is fixed on the plastic main body. One end of the cable is inserted into the plastic main body and is electrically connected to the contact body in the cavity, and an electrically connected portion is exposed in the cavity. The electrically connected portion between the cable and the contact body is exposed in the cavity, so that a clearance is formed at the welding spots between the cable and the contact body and is not injection-moulded by the internal mould, which reduces the attenuation of the cable and greatly improves the signal integrity of the product.