Coaxial Cable Connector for Corrugated Cables
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Solution Overview
Problem
Conventional coaxial cable connectors are difficult and time-consuming to install, especially on corrugated cables, requiring precise trimming and insulation removal, and often result in weak physical and electrical connections that can fail, especially in field applications like tower installations.
Innovation Solution
A coaxial cable connector that allows easy mounting without trimming the outer conductor, using a deformable elastomer to establish a strong, reliable electrical connection with both the central and outer conductors, including corrugated or smooth cables, by compressing the elastomer to form a large surface area contact and interlocking physical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used on corrugated coaxial cable, then electrical connection can be established at the peak, but installation becomes difficult and time-consuming requiring precise trimming and foam insulation removal
Solution Approach 1:
The connector is divided into separate functional components: a body portion that receives the cable, a clamping mechanism with jaws that grip the outer conductor, and a contact element that establishes electrical connection. This segmentation allows each component to perform its function independently without requiring precise trimming or foam removal, making installation easier while maintaining reliable electrical connection.
Solution Approach 2:
The clamping mechanism automatically adjusts to grip the outer conductor at the corrugation peak without requiring manual positioning or trimming. The spring-loaded jaws self-adjust to the cable diameter and corrugation geometry, and the contact element automatically establishes electrical connection when the cable is inserted, eliminating the need for precise manual trimming and foam removal.
2Reliability
If conventional connectors require precise trimming of outer conductor at peak and foam insulation removal, then electrical connection is established, but installation time increases to as many as twenty minutes
Solution Approach 1:
The connector body is pre-configured with receiving features that guide the cable into the correct position. The clamping mechanism is pre-positioned to engage the outer conductor at the corrugation peak, and the contact element is pre-aligned to establish electrical connection upon cable insertion. This preliminary preparation eliminates the need for time-consuming trimming and foam removal during installation.
Solution Approach 2:
The manual trimming and foam removal process is replaced by a mechanical clamping system that automatically engages the outer conductor. The spring-loaded jaws provide continuous clamping force without requiring precise manual positioning, and the contact element automatically establishes electrical connection through the corrugation peak, dramatically reducing installation time while maintaining connection strength.
3Reliability
If specialized tools and practice are used to attach conventional connectors, then reliable connection can be achieved, but device complexity and skill requirement increase
Solution Approach 1:
The connector performs its own alignment and positioning functions without requiring specialized tools or operator skill. The cable guide features automatically position the cable, the spring-loaded clamping mechanism self-adjusts to the correct grip force, and the contact element automatically establishes electrical connection. This self-service capability eliminates the need for specialized tools and extensive operator training.
Solution Approach 2:
The clamping force and contact pressure are controlled by spring tension rather than manual adjustment, maintaining optimal connection parameters automatically. The connector design incorporates geometric parameters that match the corrugation geometry, allowing the clamping jaws to engage at the correct location and angle without requiring operator skill or specialized tools.
4Reliability
If conventional connectors are mounted in field conditions many feet above ground on transmission towers, then connection can be established, but difficulty and risk increase significantly
Solution Approach 1:
The connector components are designed as compact, modular units that can be easily handled and assembled in difficult field conditions. The separation of the clamping mechanism from the contact element allows for simplified assembly steps that can be performed with one hand or minimal tools, reducing the difficulty and risk of installation on transmission towers.
Solution Approach 2:
The connector performs automatic alignment, clamping, and electrical connection functions without requiring precise manual manipulation or specialized tools. The spring-loaded mechanism self-adjusts to the cable, and the contact element automatically establishes electrical connection, eliminating the need for skilled operators to perform complex manual procedures at heights.
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 connector provides quick, reliable, and strong electrical and physical connections along the cable length, reducing installation time and preventing connection failures, even in challenging environments like tower tops.
Implementation Method 1
using a deformable elastomer to establish a strong, reliable electrical connection with both the central and outer conductors
Implementation Method 2
by compressing the elastomer to form a large surface area contact and interlocking physical connection
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector (10) is mounted on a coaxial cable (12) An electrical connection with the outer conductor (16) of the cable is formed by compressing an elastomer body (72) surrounding the end of the cable and pressing the body inwardly against the cable to hold a conductive member in electπcal connection with the outer conductor.