Coaxial Cable Connector Welding for PIM Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Coaxial cable connectors in harsh environments, such as cellular towers, experience performance degradation due to loose internal parts causing passive intermodulation (PIM), leading to disrupted communication and reduced data rates.
Innovation Solution
A coaxial cable connector design featuring weld joints between the center conductor and electrical contact, and between the outer conductor and the connector body, ensuring secure mechanical and electrical contact through welding processes like laser beam welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical connectors are used in coaxial cables, then assembly is easier and device complexity is lower, but reliability deteriorates due to loose internal parts causing PIM
Solution Approach 1:
The patent replaces traditional mechanical threading and tightening systems with a welding system. The welding component delivers welding energy (electrical, thermal, or electromagnetic) to fuse the outer conductor directly to the connector body, eliminating mechanical fasteners, threads, and tightening mechanisms. This substitution of mechanical connection with welding achieves superior reliability by creating a permanent, unified bond that cannot loosen or degrade over time.
2Reliability
If weld joints are used to connect outer conductor to connector body, then reliability improves by preventing loose parts, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces a welding component as an intermediary element between the outer conductor and the connector body. This welding component can be a separate element that facilitates the welding process, providing a controlled interface for energy delivery and ensuring proper alignment and contact during welding. The intermediary welding component helps manage the precision requirements by standardizing the welding interface and process.
3Object-generated harmful factors
If internal parts are secured to prevent loosening, then PIM is reduced, but ease of manufacture decreases due to additional welding processes
Solution Approach 1:
The patent merges the outer conductor and connector body into a single unified structure through welding. By fusing these components together, the patent eliminates the separation between parts that could lead to loosening and PIM generation. The merging process creates an integrated assembly where the outer conductor becomes an integral part of the connector body, removing the need for separate fastening elements and reducing the potential for connection degradation over time.
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
The design significantly reduces PIM, enhancing the reliability and performance of electronic devices connected to coaxial cables by maintaining consistent mechanical and electrical contact, thereby improving communication quality and reducing customer dissatisfaction.
Implementation Method 1
A first weld joint between a center conductor of a coaxial cable and an electrical contact of the coaxial cable connector, wherein the first weld joint is located along an outer surface of the center conductor, and a second weld joint between an outer conductor of the coaxial cable and a portion of a connector body of the coaxial cable connector
Implementation Method 2
ensuring secure mechanical and electrical contact through welding processes like laser beam welding
Data Source
AI summary
A coaxial cable device and method for establishing weld and mate connectivity across a coaxial cable. The device includes an outer conductor engager and an inner conductor engager wherein the outer conductor engager includes a weld interface for engagement with a first portion of a coaxial cable, and wherein the inner conductor engager includes a mate interface for engagement with a second portion of the cable.