Coaxial Cable Connector Welding for Passive Intermodulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting coaxial cables to connectors, such as soldering and clamping, face challenges in achieving reliable electrical and mechanical stability, particularly under outdoor conditions, due to issues like passive inter-modulation, brittleness, and moisture ingress, which affect the performance and longevity of the connection.
Innovation Solution
A method utilizing laser or electron beam welding to create a 360-degree contact at the conductor junction area, ensuring mechanical stability and preventing passive inter-modulation, while minimizing thermal distortion and material consumption, and optionally using aluminum for weight reduction and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering process is used to connect coaxial cable and connector, then electrical contact is achieved, but the connection becomes brittle and unreliable under outdoor conditions
Solution Approach 1:
The patent replaces the chemical soldering process with a mechanical compression system. A compression element is inserted into a compression chamber and actuated by a piston to compress the conductor cores together, creating a mechanical connection instead of a chemical solder joint. This mechanical connection avoids the brittleness issue of soldered joints while maintaining electrical conductivity.
Solution Approach 2:
The patent changes the connection mechanism from chemical bonding (soldering) to mechanical compression. By controlling the compression force and duration through the piston system, the conductor cores are pressed together with sufficient force to create a reliable electrical contact without the brittleness associated with soldered joints.
2Reliability
If soldering process is used, then electrical contact is achieved, but passive inter-modulation occurs due to non-perfect contact
Solution Approach 1:
The mechanical compression system ensures uniform and consistent contact pressure across the entire contact surface between conductor cores. This eliminates the non-perfect contacts that cause passive inter-modulation in soldered joints, as the compression element maintains optimal electrical contact through controlled mechanical force.
3Reliability
If soldering process is used, then connection is achieved, but manufacturing complexity increases due to multiple parameters to control
Solution Approach 1:
The patent replaces the complex thermal process of soldering (requiring control of temperature, time, material combinations, and tolerances) with a simpler mechanical compression process. The piston system provides direct mechanical force to compress the conductors, eliminating the need to control multiple thermal and material parameters while achieving reliable electrical contact.
4Ease of manufacture
If clamping process is used to connect conductors, then connection is achieved, but electrical contact quality is insufficient
Solution Approach 1:
The patent uses a controlled compression system with a piston and compression element that applies uniform pressure to the conductor cores. This is more sophisticated than simple clamping, as it ensures consistent contact quality across all conductors while maintaining ease of manufacture through an automated mechanical process.
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 method provides a stable and reliable electrical connection that withstands environmental conditions, maintaining mechanical and electrical performance by avoiding brittleness and moisture ingress, with reduced manufacturing time and material usage.
Implementation Method 1
the beam of a laser beam welding apparatus or an electron beam welding apparatus is focussed onto the conductor junction area around the outer gap
Implementation Method 2
the beam of a laser beam welding apparatus or an electron beam welding apparatus is focussed onto the conductor junction area
Implementation Method 3
concentrated application of energy at the conductor junction area
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for manufacturing an electrical connection between a coaxial cable (COAX1) and a coaxial connector (CON1), the method comprising the step of connecting at least one conductor (COAX_IC1, COAX_OC1) of the coaxial cable (COAX1) to a conductor (CON_IC1, CON_OC1) of the coaxial connector (CON 1) by a welding process, wherein the coaxial connector (CON1) is connected to an end face of the coaxial cable (COAX1) and the welding process is applied with a concentrated application of energy.