Coaxial Cable Connector Crimping Corrugated Outer Conductor

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Solution Overview

Problem

Coaxial transmission lines with aluminum outer conductors face decreased conductivity and intermodulation performance due to corrosive soldering flux and galvanic corrosion, especially with helical corrugations, leading to lower quality cables and potential failure.

Innovation Solution

A coaxial cable connector interface using a crimp portion that conforms to the corrugations of the outer conductor, eliminating the need for soldering and incorporating a sealing element and protective boot to prevent moisture ingress and corrosion, ensuring reliable contact and moisture protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If soldering is used to interface cable connectors with aluminum outer conductors, then a strong junction is achieved, but corrosive flux decreases conductivity and intermodulation performance

Engineering Contradiction:

Improvejunction strengthVSAvoidintermodulation performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent removes the soldering process entirely from the connection method. Instead of soldering the connector to the aluminum outer conductor, the invention uses a mechanical crimping interface where the connector body directly engages with the corrugated outer conductor through a crimp groove, eliminating exposure to corrosive flux and preserving conductivity and intermodulation performance.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a corrugated outer conductor with a specific crimp groove geometry as an intermediary mechanical interface. This groove engages with a corresponding crimp interface on the connector body, providing a strong mechanical junction without requiring chemical bonding through soldering, thus avoiding flux-induced corrosion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If helical corrugations are used in the outer conductor, then cable flexibility is increased, but moisture penetration paths are created leading to galvanic corrosion

Engineering Contradiction:

Improvecable flexibilityVSAvoidmoisture penetration

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent applies a conformal coating over the helical corrugations before connector assembly. This coating is applied in advance to seal the moisture penetration paths created by the helical corrugations, preventing moisture from reaching the interface between the outer conductor and connector body, thereby preventing galvanic corrosion while preserving cable flexibility.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The patent uses a protective boot as a sacrificial protective element that can be replaced if damaged. This boot provides an additional barrier against moisture penetration and physical damage to the connector interface, serving as a disposable protective layer that extends the life of the underlying corrosion-resistant interface.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If soldering flux is used to create strong connections, then junction strength is improved, but flux removal becomes extremely difficult

Engineering Contradiction:

Improveconnection strengthVSAvoidflux removal difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent completely eliminates the soldering flux from the manufacturing process by replacing the soldering operation with a mechanical crimping operation. The connector is crimped directly to the corrugated outer conductor using a crimp groove interface, requiring no flux application or removal steps, thereby simplifying the manufacturing process and eliminating flux-related contamination issues.

Inventive Principle:

Principle #2Taking out (Extraction)

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 solution maintains high intermodulation performance and prevents corrosion, allowing for high-quality coaxial transmission lines with aluminum outer conductors without compromising cable performance or causing failure, even with helical corrugations.

Implementation Method 1

The crimp portion conforms to the corrugations of the outer conductor, creating contact points between the crimp portion and the corrugations that maintain the interface between the coaxial cable and the cable connector

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

a sealing element and a protective boot for preventing moisture from penetrating the coaxial cable connector interface

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS7736181B1Coaxial cable connector interface

Publication Date: 2010.06.15 NOKIA OF AMERICA CORP

AI summary

A coaxial cable connector interface for allowing signals to be transmitted over a coaxial transmission line between devices includes a coaxial cable and a cable connector that allows the coaxial cable to be attached to the devices. The coaxial cable includes a solid outer conductor that has corrugations to increase flexibility of the coaxial cable. The cable connector has a crimp portion that surrounds an end portion of the outer conductor of the coaxial cable. The crimp portion conforms to the corrugations of the outer conductor, thereby creating an interface with the corrugations that attaches the cable connector to the coaxial cable by maintaining an axial load between the cable connector and the coaxial cable. Additionally, the coaxial cable connector interface includes a sealing element and a protective boot for preventing moisture from bridging the interface and causing cable performance reduction.