Coaxial Connector Crimp Structure to Protect Core Wire Signal Integrity
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Solution Overview
Problem
Conventional coaxial electrical connectors cause deformation of the core wire in coaxial cables during crimping, leading to deterioration of signal transmission characteristics, especially in high-frequency bands.
Innovation Solution
The electrical connector design includes a crimping member with a base end portion located between the inner and outer insulator layers of the coaxial cable, where the crimping member is crimped onto the outer conductor layer, clamping it between itself and the outer contact, thereby preventing pressure transmission to the core wire, using a configuration that includes plate-like portions and engagement features to secure the crimping member and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If strong pressure is applied to crimp the first crimping portion onto the outer conductor layer, then the outer contact is securely attached to the coaxial cable, but the core wire is crushed and deformed leading to deterioration of signal transmission characteristics
Solution Approach 1:
The patent divides the crimping function into two separate crimping portions: the first crimping portion (620) that crimps the outer contact to the outer conductor layer, and the second crimping portion (630) that crimps the outer insulator layer. This segmentation allows independent optimization of each crimping action, enabling secure attachment without transmitting excessive pressure to the core wire.
Solution Approach 2:
The patent introduces the second crimping portion (630) as an intermediary element that crimps the outer insulator layer (540) to provide additional support and stabilization. This intermediary structure helps distribute the crimping forces and prevents direct transmission of excessive pressure to the core wire (510), thereby maintaining signal transmission quality while ensuring secure attachment.
2Ease of manufacture
If the outer contact is crimped directly onto the outer conductor layer without additional support structures, then the manufacturing process is simple, but the core wire deformation cannot be prevented under crimping pressure
Solution Approach 1:
The outer contact (600) is segmented into multiple functional portions: the cylindrical portion (610), the first crimping portion (620) for crimping the outer conductor layer, and the second crimping portion (630) for crimping the outer insulator layer. This segmentation enables precise control over the crimping process, ensuring the core wire remains undisturbed while achieving secure attachment.
Solution Approach 2:
The patent employs a preliminary action by designing the outer contact with pre-positioned crimping portions that are specifically shaped and oriented to engage with the coaxial cable structure before final crimping. The first crimping portion (620) is positioned to crimp the outer conductor layer, while the second crimping portion (630) is positioned to crimp the outer insulator layer, ensuring proper alignment and preventing core wire deformation from the outset.
Data Source
AI summary
An electrical connector includes a contact pin to be connected to a core wire of a coaxial cable, an insulating housing for holding the contact pin therein, a cylindrical outer contact covering the housing and a crimping member for attaching the outer contact to the coaxial cable. A base end portion of the outer contact is located between an inner insulator layer and an outer conductor layer of the coaxial cable. The outer contact is attached to the coaxial cable by crimping the crimping member onto the outer conductor layer of the coaxial cable located on the base end portion of the outer contact.