Cable Connector Sleeve Radial Constriction for Pull-Off Force
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Solution Overview
Problem
Existing cables for signal transmission in motor vehicles and aircraft require a balance between robustness and ease of assembly, with a need for high data rate transmission and a defined minimum pull-off force in the plug-in coupling element, while maintaining cost-effectiveness.
Innovation Solution
A cable design featuring a plug-in coupling element with an inner conductor, insulation, screen, sleeve, and support sleeve, where the sleeve has distinct sections with a radial narrowing and webs extending axially, allowing for secure electrical contact and high pull-off force through material selection with different moduli of elasticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug-in coupling element is made robust with high pull-off force, then connection reliability is improved, but manufacturing complexity and effort increase
Solution Approach 1:
The coupling element is divided into functionally distinct sections: a support sleeve with axially extending webs for mechanical support and screen attachment, and a separate sleeve with a radial narrowing for electrical contact and positioning. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process through modular assembly.
Solution Approach 2:
The sleeve features a radial narrowing (constriction) at a specific location that creates a localized contact point with the screen. This local quality change provides enhanced electrical contact and mechanical positioning exactly where needed, while the rest of the sleeve maintains its structural integrity and simplicity for easy manufacturing.
2Reliability
If the cable is designed for high data rate transmission, then signal quality is improved, but manufacturing precision requirements increase
Solution Approach 1:
The support sleeve with axially extending webs is pre-formed to provide a stable foundation that automatically positions the screen and inner conductor in correct alignment during assembly. The radial narrowing in the sleeve is also pre-positioned to ensure proper contact points, eliminating the need for complex post-assembly adjustments and ensuring high signal quality through consistent geometric relationships.
3Ease of manufacture
If the cable structure is simplified for cost-effective manufacturing, then production cost is reduced, but connection robustness deteriorates
Solution Approach 1:
The cable employs a composite structure combining different materials with complementary properties: the support sleeve provides mechanical strength and structural support, while the outer sleeve with radial narrowing provides electrical conductivity and precise positioning. This composite approach achieves high pull-off force and robust connections through material synergy rather than over-engineering a single component, maintaining manufacturing simplicity.
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 cable achieves robustness and high pull-off force while minimizing manufacturing effort, enabling reliable high-data-rate signal transmission and withstanding torsional stresses, particularly suitable for miniaturized applications.
Implementation Method 1
The support sleeve has a plurality of webs which extend in a direction with an axial component
Implementation Method 2
The second section has a radial narrowing, so that the sleeve has a narrowed internal cross-section in this section
Implementation Method 3
the sleeve is made from a first material and the support sleeve is made from a second material, which differs from the first material. In particular, both materials are metallic materials. According to the invention, the first material has a lower modulus of elasticity than the second material
Implementation Method 4
The cable is configured such that the second section is located between the first section and the third section in the axial direction
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a cable with a plug-in connector element comprising an inner conductor (1), insulation (2) arranged radially outside the inner conductor (1), a shield (3) arranged radially outside the insulation (2), a sleeve (4), a jacket (5), and a support sleeve (6). The support sleeve has several webs (6.2) extending in an axial direction. The sleeve (4) has a first section (4.1), a second section (4.2), and a third section (4.3), the first and second sections (4.1, 4.2) being arranged radially outside the support sleeve (6). The second section (4.2) has a radial constriction, with the sleeve (4) enclosing the webs (6.2) in the second section (4.2). Furthermore, the sleeve (4) encloses the jacket (5) in the third section (4.3). The second section (4.2) is in the axial direction (x) between the first section (4.1) and the third section (4.3).