Coaxial Connector Assembly With Controlled Sheath Compression
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Solution Overview
Problem
Conventional coaxial cable connector assemblies with support clamps or crimp tubes compromise high-frequency properties due to excessive compression and shape changes, while achieving high holding forces is challenging.
Innovation Solution
A method involving a coaxial cable assembly where the outer conductor part is designed with a connecting section that has a reduced inner diameter, compressing the cable sheath in a controlled manner to maintain high-frequency properties while achieving strong holding forces, without additional support clamps or crimp tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support clamp, sleeve, crimp clamp, or separate crimp tube is used to achieve high holding forces, then the mechanical reliability is improved, but the high-frequency characteristics are worsened due to excessive compression and deformation
Solution Approach 1:
The invention changes the geometric parameters of the connecting section, specifically reducing its inner diameter to compress the cable sheath uniformly. This parameter change allows achieving high holding forces through controlled compression rather than excessive deformation, thereby maintaining high-frequency characteristics while improving mechanical reliability
Solution Approach 2:
Instead of adding external support clamps or crimp tubes to achieve holding forces, the invention inverts the approach by making the connecting section itself the load-bearing element. The connecting section is designed to be pushed over the cable, reducing its inner diameter to create the necessary holding force directly at the connection point, eliminating the need for additional components
2Strength
If additional support clamps or crimp tubes are added to increase holding forces, then the mechanical strength is improved, but the device complexity increases
Solution Approach 1:
The invention merges the functions of the connecting section and the support structure into a single integrated component. The connecting section is designed to perform both the electrical connection function and the mechanical support function, eliminating the need for separate support clamps, sleeves, or crimp tubes, thereby reducing assembly complexity while maintaining holding forces
Solution Approach 2:
The connecting section is designed as a multi-functional component that simultaneously provides electrical connection, mechanical support, and structural integrity. By making the connecting section universal and capable of performing multiple functions, the invention eliminates the need for additional specialized components, simplifying the overall assembly
3Force
If the inner diameter of the connecting section is reduced to compress the cable sheath, then the holding forces are improved, but the compression must be controlled to avoid deforming the insulator and affecting high-frequency properties
Solution Approach 1:
The invention applies local quality by designing the connecting section with a reduced inner diameter that creates controlled compression specifically at the cable sheath level. The compression is localized to the area between the connecting section and the cable sheath, preventing excessive deformation of the insulator while achieving sufficient holding forces through targeted compression
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 approach enhances holding forces significantly while minimizing excessive compression, thereby preserving high-frequency performance and simplifying the manufacturing process.
Implementation Method 1
the outer conductor part with the connecting section of the outer conductor part is pushed over the first cable section, reducing the inner diameter of the connecting section, whereby the cable sheath is compressed at least in a first partial area of the connecting section and the wires lie against the inner wall of the connecting section and the cable sheath
Data Source
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AI summary
A method for manufacturing an assembly (40, 50) from a connector (41), particularly for high-frequency applications, and a coaxial cable (4) or a component for such an assembly (40, 50) is presented, comprising: - providing an outer conductor part (1, 5), wherein the outer conductor part (1, 5) has at least one connection section (21) with an inner wall that is at least partially designed as a hollow cylinder, - providing an inner conductor part (3, 7) and an insulating part (2, 6), - providing a coaxial cable (4), wherein the coaxial cable (4) has an outer conductor (17) having wires, an inner conductor (14) that is at least partially arranged inside the outer conductor (17), an insulator (15) that is at least partially arranged inside the outer conductor (17) and at least partially encloses the inner conductor (14), and a cable jacket (18) that at least partially encloses the outer conductor (17).- Stripping an outer conductor section (17b) of the coaxial cable (4), - Turning the stripped outer conductor section (17b) inside out around a first cable section (22) of the coaxial cable (4) and arranging the wires on the outside of the cable sheath (18) in the first cable section (22), - Joining the coaxial cable (4) with the outer conductor section (1, 5) to form the assembly (40, 50) or component, wherein the outer conductor section (1, 5) with the connecting section (21) of the outer conductor section (1, 5) is pushed over the first cable section (22), - Reducing the inner diameter of the connecting section (21) whereby the cable sheath (18) is compressed at least in a first sub-region (24) of the connecting section (21) and the wires are in contact with the inner wall of the connecting section (21) and the cable sheath (18), wherein the first sub-region (24) comprises at least 70% of an area (25) of the connecting section (21),in which the wires are arranged between the inner wall and the cable sheath (18). Furthermore, an assembly and the use of such an assembly are presented.