Coaxial Cable Jacket Diameter Standardization for Reliable Sealing
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Solution Overview
Problem
Coaxial cable connectors face issues with moisture migration due to variations in outer jacket diameters and surface irregularities, leading to inconsistent sealing and potential electrical degradation, especially at the interface between the cable jacket and the back nut.
Innovation Solution
A method involving the partial removal of the coaxial cable jacket and outer conductor to create a consistently reduced outer diameter section, combined with a specialized preparation tool to facilitate this process, ensuring a reliable and consistent seal with the coaxial connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a sealing is installed in the back nut to prevent moisture migration, then moisture sealing is improved, but the seal reliability deteriorates due to variations in cable jacket outer diameter causing inconsistent sealing pressure
Solution Approach 1:
The invention changes the physical state of the cable jacket by melting and reforming the outer surface to create a smooth, uniform diameter. This parameter change in surface morphology ensures consistent sealing pressure on the O-ring, making sealing pressure independent of manufacturing tolerances and irregularities in the original cable jacket.
Solution Approach 2:
The invention performs preliminary action by preparing the cable jacket surface before the connector assembly is finalized. The melting and reforming process is applied to the cable end prior to insertion, pre-conditioning the surface to ensure optimal sealing conditions will be achieved when the connector is assembled.
2Ease of manufacture
If manufacturing tolerances of the cable jacket are relaxed to reduce production costs, then ease of manufacture is improved, but the seal effectiveness deteriorates due to diameter variations exceeding the 0.30-0.50 mm range required for proper O-ring pressurization
Solution Approach 1:
The invention applies thermal energy to change the physical state of the cable jacket material from solid to molten and back to solid, transforming the surface geometry. This parameter change in temperature and material state allows the creation of a uniform diameter surface that compensates for relaxed manufacturing tolerances in the original cable jacket.
Solution Approach 2:
The invention introduces heat as an intermediary medium to transform the cable jacket surface. The heating element acts as a mediator that temporarily alters the material properties of the cable jacket, allowing it to be reshaped into a form that ensures proper sealing, independent of the original manufacturing precision.
3Reliability
If the outer diameter of the cable jacket is strictly controlled to maintain O-ring pressurization within 10-20% of thickness, then seal reliability is improved, but manufacturing precision requirements increase significantly
Solution Approach 1:
The invention changes the surface geometry parameter of the cable jacket through melting and reforming. By altering the physical state and reshaping the material, it creates a uniform diameter surface that ensures reliable sealing without imposing strict manufacturing precision requirements on the original cable production process.
Solution Approach 2:
The invention extracts the problematic irregularities and diameter variations from the cable jacket by melting away the outer layer and reforming it. This removal and reformation process eliminates the need for tight manufacturing tolerances, as the new uniform surface is created independently of the original dimensional variations.
4Ease of operation
If surface irregularities such as corrugations, valleys, nicks, and scratches are present on the cable jacket, then ease of installation is improved, but the seal effectiveness deteriorates due to leakage paths developing at these imperfections
Solution Approach 1:
The invention changes the surface topology parameter by melting and reforming the cable jacket outer surface. This process eliminates valleys, nicks, scratches, and grooves by redistributing the material, creating a smooth surface that prevents leakage paths while maintaining the protective function of the jacket.
Solution Approach 2:
The invention converts the harmful effect of surface irregularities into a benefit by using heat to melt and smooth the surface. The same thermal energy that could potentially damage the cable is instead used to eliminate the defects, transforming the problematic rough surface into a smooth, seal-friendly surface that enhances moisture protection.
Data Source
AI summary
A method of preparing the end of a coaxial cable for insertion within a coaxial cable connector involves stripping the cable jacket from the end of the cable, and reducing the outer diameter of the cable jacket portion lying adjacent the stripped portion of the jacket to a relatively constant reduced diameter. The reduced diameter portion of the cable jacket can then be reliably sealed to the back nut of the coaxial connector by an O-ring. A related preparation tool is disclosed for simultaneously stripping the cable jacket from the end of the cable, and reducing the outer diameter of the cable jacket portion lying adjacent the stripped portion, as the tool is rotated about the end of the coaxial cable. The tool may also serve to remove a portion of the outer conductor, as well as a coring member to remove dielectric surrounding the inner conductor of the cable.