Electrical Connector With Guide Portion for Cable Positioning
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Solution Overview
Problem
Existing connectors require multiple components and complex assembly, and may deform shielded wires or cables during connection, increasing the number of components and assembly complexity, and requiring additional steps to correct deformations.
Innovation Solution
A connector design featuring a cylindrical body with a guide portion for decentering the cable, a U-shaped terminal portion, and crimping portions, allowing for reliable positioning and connection of core wires and terminals with reduced components, enabling both press-crimping and soldering connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a projection is formed inside a hook of insulating resin to push up the center connector pin, then the connector pin can be connected to the output terminal, but the number of components increases and assembling becomes complicated
Solution Approach 1:
The insulating resin body integrates multiple functions: it serves as the housing structure, contains the projection for positioning the center connector pin, and provides the mounting interface for the outer conductor. By combining these elements into a single integrated component rather than separate parts, the design reduces the total number of components while maintaining the reliable connection mechanism.
2Reliability
If the insulating resin is fitted into the outer conductor with a projection to push the center connector pin, then connection is achieved, but assembling becomes complicated
Solution Approach 1:
The projection is pre-formed as an integral part of the insulating resin body during the molding process. This preliminary formation of the positioning feature eliminates the need for separate assembly steps to install positioning elements, thereby simplifying the overall assembly process while ensuring reliable connection of the center connector pin to the output terminal.
3Reliability
If a caulking tube with extended tube length is used to close one opening, then the opening can be closed, but the device complexity increases
Solution Approach 1:
The insulating resin body integrates the opening closure function directly into its structure. The resin body itself forms the closure for the opening where the center conductor is press-crimped, eliminating the need for a separate caulking tube. This integration reduces component complexity while maintaining reliable opening closure.
4Manufacturing precision
If a blade-shaped part with a sharp end is used to decenter the cable, then positioning is achieved, but the copper foil tape or shielded wire may be deformed
Solution Approach 1:
The insulating resin body incorporates a localized deformation-resistant structure at the specific location where cable decentering is needed. This localized structural feature provides the necessary positioning function while being designed to avoid excessive stress concentration that would cause deformation of the copper foil tape or shielded wire.
Solution Approach 2:
The insulating resin body combines material properties that provide both the structural rigidity needed for precise cable positioning and the surface characteristics that prevent deformation of adjacent conductive elements. The composite structure allows different regions of the resin body to have optimized properties for their specific functions.
Data Source
AI summary
A connector to be connected to a cable 41 includes an outer conductor having a first cylindrical portion 33 and a second cylindrical portion 35 connected to each other. The first cylindrical portion holds a conductive contact 11. The second cylindrical portion has a guide portion 35a. A cable inserted into the second cylindrical portion is decentered by the guide portion in a predetermined direction in a predetermined radial direction.