Connector Outer Conductor Folding Structure for Seam Opening Strength
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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 that can deform under mechanical stress, requiring additional welding and complicating the manufacturing process.
Innovation Solution
The outer conductor is designed with a stamped outer conductor matrix featuring a variable-diameter structure and folding parts with process grooves, allowing for a seamless stamping process that enhances structural strength and reduces the likelihood of seam opening, while maintaining impedance adjustment capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the outer conductor is processed by oppositely stamping two halves to form a material bridge connection, then the variable-diameter treatment can be achieved to match the insulating element, but the seam opening is prone to deformation and opening under mechanical stress, requiring additional welding processes
Solution Approach 1:
The outer conductor is divided into a body portion and an end portion that are separately formed and then connected through material bridge portions. This segmentation allows each part to be optimized independently - the body portion can be precisely stamped to achieve the required variable-diameter treatment for impedance matching, while the end portion can be designed with sufficient strength to prevent seam opening deformation, eliminating the need for additional welding processes.
Solution Approach 2:
The material bridge portions serve dual functions by simultaneously connecting the body portion and end portion structurally while also providing the necessary mechanical strength to prevent seam opening. This merging of connection and reinforcement functions into a single structural element simplifies the overall processing process by eliminating separate welding operations.
2Manufacturing precision
If the outer conductor ring is reduced in diameter relative to the outer conductor matrix, then the characteristic impedance can be adjusted, but the overhanging arm is prone to bending outward under axial tension, driving the seam opening to open
Solution Approach 1:
By segmenting the outer conductor into body and end portions connected by material bridges, the design allows the end portion to be optimized for tensile strength while the body portion maintains the reduced diameter for impedance control. The material bridge portions transfer axial tension forces effectively, preventing the bending outward that would otherwise occur in a monolithic reduced-diameter structure.
Solution Approach 2:
The outer conductor employs a composite structure combining different geometric configurations in its body and end portions, connected through material bridges. This composite approach allows each section to be optimized for its specific function - impedance matching in the body and mechanical strength in the end portion - while working together as an integrated component.
3Strength
If welding process is added at the seam opening to prevent opening, then the structural strength can be improved, but the processing complexity and cost increase
Solution Approach 1:
The design extracts the welding operation from the manufacturing process by incorporating material bridge portions that provide inherent mechanical strength through their structural design. The material bridges are formed integrally with the outer conductor components during stamping, eliminating the need for separate welding processes while maintaining the necessary strength to prevent seam opening under operational stresses.
Data Source
AI summary
An outer conductor of the connector includes a stamped outer conductor matrix, and a variable-diameter structure with a reduced radial size at a front end of the outer conductor matrix; a folding part folded inward and with a backward tail end at the front end of the outer conductor matrix, and the folding part forms the variable-diameter structure; and the folding part includes 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 includes 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.