Cable Connector Ferrule Locking for Stable Crimp and Signal Integrity
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Solution Overview
Problem
Existing connectors with crimping ferrules face challenges in achieving reliable axial and rotational locking of the ferrule relative to the cable and ground body without degrading electrical performance, particularly at high frequencies, due to demanding crimping forces and potential slippage under mechanical stress.
Innovation Solution
A connector subassembly with a ferrule designed to provide axial and rotational stops through through openings and protrusions, allowing for precise crimping that limits slippage and maintains electrical performance by ensuring secure attachment to the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If demanding crimping forces are applied to secure the ferrule to the cable, then mechanical holding force is improved, but cable deformation and electrical performance degradation occur
Solution Approach 1:
The connector is divided into multiple functional components: a ferrule for initial cable attachment, a shielding body for electromagnetic protection, and a housing for structural support. Each component performs a specific function, allowing the crimping force to be distributed and controlled locally rather than applied uniformly, thus securing mechanical holding force while minimizing cable deformation
Solution Approach 2:
The ferrule acts as an intermediary element between the cable and the shielding body. It first crimps onto the cable to provide initial mechanical support, then the shielding body crimps onto the ferrule. This intermediate structure allows secure attachment while protecting the cable from direct exposure to high crimping forces that would cause deformation
2Strength
If the ferrule is crimped too tightly on the cable, then mechanical holding force is improved, but cable deformation and electrical impedance degradation occur
Solution Approach 1:
The ferrule and shielding body are designed with specific local geometries at their crimping zones. The ferrule has a tapered interior surface that matches the cable geometry, distributing crimping force evenly. The shielding body has corresponding localized features that engage with the ferrule. These local quality adaptations ensure precise crimping that achieves mechanical strength without deforming the cable or altering electrical impedance
3Reliability
If the ferrule is crimped too loosely to preserve signal transmission performance, then electrical performance is maintained, but slippage and mechanical instability occur
Solution Approach 1:
The ferrule is nested within the shielding body, creating a hierarchical structure where the ferrule provides initial mechanical support and the shielding body provides additional stabilization. This nested arrangement allows the ferrule to be crimped with sufficient force to prevent slippage while the outer shielding body protects the overall assembly and maintains mechanical stability without requiring excessive crimping force on the cable itself
4Stability of the object's composition
If protrusions and through openings are added to the ferrule for axial and rotational locking, then mechanical stability is improved, but device complexity increases
Solution Approach 1:
The ferrule incorporates asymmetric features including protrusions at specific angular positions and corresponding through openings in the shielding body. These asymmetric elements provide rotational locking by preventing relative rotation between the ferrule and shielding body, while the axial stops prevent axial displacement. The asymmetric design achieves multi-directional stability with minimal additional structural complexity
Data Source
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AI summary
Connector subassembly or connector for a cable with at least one insulated electrical wire, comprising a metal body housing at least one central contact connected to a cable wire and comprising a rear crimping portion around a crimping ferrule on the cable. The invention relates to a subassembly for a connector or connector (1), intended to be electrically connected to an electrical cable (2) comprising at least one insulated wire comprising a core (21) and an electrically insulating sheath (24), a metal braid (23) surrounding the at least one insulated wire, an outer sheath (20) made of electrically insulating material surrounding the metal braid. The subassembly comprises a ferrule crimped first onto the metal braid of the cable in a configuration allowing a rear axial stop against the outer sheath of the cable.