Dividing-Insulator Splice Connector for Capacitive Coupling Control
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Solution Overview
Problem
Existing methods for splicing electrical cables with conductor pairs, such as unshielded twisted pair cables, fail to effectively control capacitive coupling, leading to impedance and frequency response issues, and are not suitable for harsh environments like automotive or aerospace applications.
Innovation Solution
An electrical splice connector featuring crimped splice terminals and a dividing insulator with controlled capacitive coupling, utilizing a dielectric material with cavities and a separating wall to manage electrical impedance, and covered with heat shrink tubing for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional splicing methods (twisting, IDC, press fit) are used to connect electrical cables, then the splicing process is simple and easy to manufacture, but the capacitive coupling between contact pairs is not well controlled leading to impedance and frequency response issues
Solution Approach 1:
The splice connector is divided into separate contact pairs with individual cavities in the insulator body. Each contact pair is isolated in its own cavity, allowing independent control of capacitive coupling for each pair while maintaining overall connector functionality.
Solution Approach 2:
The insulator body acts as an intermediary element between contact pairs, with its dielectric material and cavity structure specifically designed to control capacitive coupling. The insulator mediates the electrical field between conductors to achieve precise impedance control.
2Reliability
If traditional splicing methods are used, then the device structure is simple, but the splice connection is not suitable for harsh environments such as automotive or aerospace applications
Solution Approach 1:
The splice connector features a nested structure with contact pairs positioned within cavities of the insulator body, which is then enclosed by a protective outer shell. This nested arrangement protects the electrical connections from environmental factors while maintaining a compact form factor suitable for harsh environments.
Solution Approach 2:
The splice connector combines multiple materials with different properties: conductive materials for contacts, dielectric materials for the insulator body to control electrical fields, and protective materials for the outer shell. This composite structure provides both electrical performance and environmental durability.
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 solution provides a reliable, low-impedance splice connection with reduced signal attenuation, suitable for harsh environments, by effectively controlling capacitive coupling and maintaining mechanical strength.
Implementation Method 1
the capacitive coupling between the contact pairs is not well controlled which may affect the impedance of the splice connection
Implementation Method 2
a dividing insulator formed of a dielectric material having a first cavity in which the first splice terminal is disposed and having a second cavity in which the second splice terminal is disposed
Implementation Method 3
a first splice terminal crimped to a first wire conductor of a first wire cable and crimped to a first wire conductor of a second wire cable
Data Source
Figure 1~2
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Figure 6
AI summary
An electrical splice connector (100, 200) is disclosed, comprising a first splice terminal (202) crimped to wire conductors (208, 212) of two wire cables (210, 214) and a second splice terminal (204) crimped to wire conductors (216, 218) of the same cables (210, 214). The connector includes a dividing insulator (206, 502) made of dielectric material with separate cavities (220, 222) for each splice terminal (202, 204), divided by a dielectric wall (224, 506). This design ensures proper insulation and separation between the two splice terminals, enhancing the safety and reliability of the electrical connection.