Coaxial Cable Crimp Connector Sleeve Design
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Solution Overview
Problem
Prior coaxial cable crimp connectors face difficulties in separating the outer conductor from the cable dielectric for connector installation and achieving reliable environmental seals, leading to challenges in electrical characteristics and installation efficiency.
Innovation Solution
A crimp connector design that eliminates the integral inner sleeve, using a separate cylindrical sleeve with a textured surface and beveled edges to facilitate easy insertion and a crimp area with adjustable dimensions for standard hand tools, allowing for a secure mechanical and electrical connection with improved environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an integral inner sleeve is used to prevent cable collapse during crimping, then mechanical support is improved, but installation difficulty increases due to inability to separate outer conductor from dielectric
Solution Approach 1:
The connector is divided into separate components: the body and the cylindrical sleeve are distinct parts that can be assembled independently. The sleeve is inserted into the body first, then the cable is installed, allowing the outer conductor to be separated from the dielectric without requiring the sleeve to be present during cable preparation.
Solution Approach 2:
The cylindrical sleeve is pre-inserted into the connector body before cable installation. This preliminary positioning of the sleeve provides the necessary mechanical support structure in place before the cable is prepared and inserted, eliminating the need for the sleeve to be integrated with the cable assembly process.
2Ease of operation
If the annular groove is dimensioned to receive the outer conductor easily, then ease of insertion is improved, but body deformation distance increases causing fracturing
Solution Approach 1:
The load distribution is segmented between the connector body and the cylindrical sleeve. The sleeve acts as a reinforcement element that shares the crimping load, allowing the annular groove to be larger for easier insertion while the sleeve prevents excessive body deformation during crimping.
Solution Approach 2:
The connector assembly combines the body material with the cylindrical sleeve material to create a composite structure. This composite design allows the groove to be optimized for ease of insertion while the sleeve provides additional structural support to prevent body fracturing during crimping operations.
3Reliability
If environmental seals are added to prevent moisture infiltration, then reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The environmental sealing function is merged with the existing cylindrical sleeve and body structure. The sleeve serves dual purposes: providing mechanical reinforcement during crimping and acting as a barrier to moisture infiltration, eliminating the need for separate sealing components.
Solution Approach 2:
The cylindrical sleeve is designed with multi-functionality: it provides mechanical support during crimping, facilitates cable installation through its textured surface and beveled edges, and serves as an environmental seal barrier. This universal component reduces the total number of parts and simplifies manufacturing.
Data Source
AI summary
A connector for semi-rigid outer conductor coaxial cable having a body provided with a connection interface at a connector end, a body bore and a crimp area around an outer surface of the body. The body bore dimensioned to receive the outer conductor together with a cylindrical sleeve dimensioned to receive the outer conductor therethrough when the outer conductor is folded back over the sleeve, to a position along the body bore corresponding to the crimp area.