Connector Outer Conductor Folding Structure for Stable Seam Openings
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Solution Overview
Problem
The existing outer conductor structures in connectors, particularly in vehicle-mounted high-speed connectors, face issues of complex processing and high costs due to seam openings prone to deformation under tension, requiring additional welding processes.
Innovation Solution
A stamped outer conductor matrix with a variable-diameter structure and folding parts having process grooves allows for a simplified circle-holding stamping process, forming a seam opening on one side while maintaining structural integrity and adjusting impedance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the outer conductor matrix and outer conductor ring are connected by material bridge connection, then the structure can be formed by oppositely stamping two halves, but the seam opening is prone to opening under tension requiring additional welding process
Solution Approach 1:
The invention merges the outer conductor matrix and outer conductor ring into a single integrally formed component through one stamping process, eliminating the material bridge connection and seam opening. This integration resolves the contradiction by maintaining manufacturing simplicity while eliminating the reliability issue of seam opening under tension.
Solution Approach 2:
The invention segments the outer conductor into a matrix portion and a ring portion that are integrally formed, with the ring portion having a reduced diameter relative to the matrix. This segmentation allows the structure to accommodate the insulating element's outer diameter change while maintaining integral strength without requiring separate components or welding.
2Manufacturing precision
If the outer conductor ring is reduced in diameter relative to the outer conductor matrix, then the characteristic impedance can be reduced, but the front end of the outer conductor matrix is subjected to outward tension causing deformation
Solution Approach 1:
The invention employs a curved folding part that folds inward and extends backward, creating a smooth transition zone between the matrix and ring portions. This curved structure distributes the outward tension forces along the fold, preventing localized deformation while maintaining the reduced diameter of the ring portion for proper impedance matching.
Solution Approach 2:
The folding part is pre-formed during the stamping process to create an inward fold with extended backward tail end. This preliminary structural preparation ensures that when the connector is assembled and subjected to tension, the pre-formed fold already provides the necessary structural reinforcement to resist deformation.
3Shape
If a folding part folded inward is arranged at the front end of the outer conductor matrix, then the variable-diameter structure can be formed, but material accumulation may occur requiring process grooves
Solution Approach 1:
The invention extracts the excess material that would otherwise accumulate during the folding process by designing process grooves that extend through the folding part. These grooves allow the material to be taken out or redistributed during stamping, enabling the formation of the variable-diameter structure without creating unwanted material buildup that would complicate the manufacturing process.
Data Source
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AI summary
The present invention relates to the technical field of connectors, and in particular to an outer conductor of a connector and a method for forming the outer conductor of the connector. The outer conductor of the connector includes a stamped outer conductor matrix, and a variable-diameter structure with a reduced radial size is arranged at a front end of the outer conductor matrix; a folding part folded inward and with a backward tail end is arranged at the front end of the outer conductor matrix, and the folding part forms the variable-diameter structure; and the folding part is provided with process grooves penetrating the tail end of the folding part and used to adapt to a circle-holding stamping process to form a seam opening at a side of the outer conductor matrix. The folding part is provided with the process grooves penetrating forward, and a material of the folding part with a reduced distribution diameter can deform and expand into the process grooves, so the folding part of the outer conductor can form the seam opening at a side of the outer conductor through circle-holding stamping processing. The outer conductor with only one seam opening can bear a higher tension, so that the opening probability of the seam opening in the folding part and the cost are reduced, and the process is simplified.