Cable Arrangement Filler Element Impedance
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Solution Overview
Problem
High-frequency cable connections experience impedance discontinuities due to air-filled cavities formed between the outer conductor contact and the insulator part, leading to adverse effects on signal transmission, especially in the two- or three-digit gigahertz range.
Innovation Solution
A cable arrangement with an electrically conductive and elastic filling element is introduced to replace air in the cavity, ensuring a constant impedance curve by filling the area between the axial end of the outer conductor and the change in diameter of the outer conductor contact element, thus optimizing high-frequency signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer conductor is folded back around the support sleeve and crimped to the outer conductor contact element, then a mechanically stable connection is achieved, but an air-filled cavity forms between the outer conductor contact and the insulator part causing impedance discontinuity
Solution Approach 1:
A filler element is introduced as an intermediary substance between the outer conductor contact element and the insulator part. This filler element fills the cavity that would otherwise be filled with air, thereby eliminating the impedance discontinuity while not interfering with the mechanical crimping connection between the outer conductor and the contact element.
Solution Approach 2:
The dielectric parameter of the space between the outer conductor contact and the insulator is changed from air (low dielectric constant) to a filler material with appropriate dielectric properties. This parameter change ensures that the impedance remains continuous along the signal path, matching the characteristic impedance of the coaxial cable.
2Manufacturing precision
If the crimp sleeve has a radial constriction to direct the outer conductor contact towards the insulator part, then impedance matching is improved, but manufacturing tolerances cause cavity formation and impedance disturbance
Solution Approach 1:
The filler element is placed in advance into the cavity formed by the radial constriction of the crimp sleeve. This beforehand cushioning compensates for the impedance disturbance that would otherwise be caused by manufacturing tolerances and assembly variations, ensuring consistent impedance matching across all produced cables.
3Reliability
If the outer conductor contact element has a change in diameter to achieve coaxiality, then electrical contact is optimized, but a cavity forms between the axial end of the outer conductor and the change in diameter
Solution Approach 1:
The filler element serves as an intermediary that occupies the cavity created by the diameter change of the outer conductor contact element. This allows the contact element to maintain its optimized geometry for electrical contact while the filler eliminates the harmful air cavity that would cause impedance discontinuity.
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
The solution achieves a constant impedance curve along the high-frequency signal path, enhancing transmission behavior for high-frequency signals up to the two- or three-digit gigahertz range by eliminating air-filled cavities with an electrically conductive filling element.
Implementation Method 1
the filler element is electrically conductive and elastic and is configured to reduce air entrapment in the area between the axial end of the folded-back outer conductor and the change in diameter of the outer conductor contact element
Implementation Method 2
the filler element is electrically conductive and elastic and is configured to reduce air entrapment
Data Source
Figure 1A~1B
Figure 2A~2C
AI summary
The present invention relates to a cable arrangement with a cable which has an external conductor, and with an external conductor contact element which is connected electrically to the external conductor and has a diameter change. Furthermore, the cable arrangement has a filling element which is electrically conductive in a region of the diameter change. The filling element is set up to reduce an air inclusion in the region of the diameter change.