Automotive Coaxial Cable Splice for Impedance-Matched Repair
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Solution Overview
Problem
Existing methods for repairing damaged automotive coaxial cables often result in performance degradation due to changes in the conductor-to-dielectric ratio and air pockets, leading to signal interference and noise.
Innovation Solution
A splicing device and method that includes a core connector terminal and a tubular insulation member, with a conductive spacing member to maintain a consistent conductor-to-dielectric ratio and prevent air pockets, ensuring precise fit and electrical coupling of coaxial cables through crimping and an outer conductive sheath to maintain signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional removal and replacement of damaged coaxial cables is performed, then the damaged cable is completely replaced, but the repair process is time-consuming and costly
Solution Approach 1:
The cable repair device segments the coaxial cable into distinct functional zones: the original cable sections, the transition region with tapered dielectric, and the spliced connector section. This segmentation allows the damaged portion to be repaired in-place rather than replacing the entire cable, significantly reducing repair time and material waste while maintaining signal integrity throughout the cable assembly.
Solution Approach 2:
The device incorporates pre-configured tapered dielectric sections and precision-machined connectors that are prepared in advance. The tapered dielectric is pre-formed to provide gradual impedance transitions, and connectors are pre-assembled with precise tolerances. This preliminary preparation eliminates time-consuming field adjustments and ensures consistent repair quality.
2Device complexity
If a simple connector is used to join cable sections, then the repair process is simplified, but signal interference and noise increase due to impedance mismatches
Solution Approach 1:
The dielectric material undergoes a gradual parameter change through its tapered geometry, transitioning from the original cable's dielectric constant and dimensions to the connector's different dimensions. This continuous parameter change creates a smooth impedance transition rather than an abrupt step change, minimizing signal reflections and interference while maintaining a relatively simple overall connector structure.
Solution Approach 2:
The tapered dielectric section is localized to the transition region between cable and connector, while the rest of the cable maintains its original uniform structure. This localized modification provides the necessary impedance matching only where needed, without unnecessarily complicating the entire cable assembly or requiring complex connectors throughout.
3Ease of manufacture
If air pockets are present in the connector assembly, then the assembly process becomes easier, but signal transmission quality degrades due to impedance variations
Solution Approach 1:
The tapered dielectric acts as an intermediary element between the conductor and the outer insulation layers. Its gradual geometry change provides a buffer zone that accommodates minor assembly variations and tolerances, preventing air pockets from forming at critical interfaces. This intermediary structure maintains consistent electrical properties even when manufacturing tolerances vary slightly, ensuring reliable signal transmission without requiring extremely tight assembly precision.
4Ease of operation
If the conductor-to-dielectric ratio is changed during repair, then the cable can be reassembled, but characteristic impedance changes causing signal degradation
Solution Approach 1:
The tapered dielectric provides a controlled, gradual parameter change in the conductor-to-dielectric ratio along its length. Rather than maintaining a constant ratio throughout (which would require complex geometry), the ratio transitions smoothly from one value to another, creating a continuous impedance profile. This controlled parameter change allows easy reassembly while maintaining signal integrity through minimal reflections.
Data Source
AI summary
A coaxial cable splicing device includes a core connector terminal and a tubular insulation member. The core connector terminal includes a first connection member configured to receive a first core of a first coaxial cable and a second connection member configured to receive a second core of a second coaxial cable therein. A conductive spacing member is positioned between the first connection member and the second connection member. The conductive spacing member includes a first stop surface to engage the first core and a second stop surface to engage the second core. The tubular insulation member includes a cavity configured to receive the core connector terminal, the first core of the first coaxial cable, and the second core of the second coaxial cable therein.