Ferrule Crimping for Cable Diameter Adaptability
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Solution Overview
Problem
Existing electrical connectors face challenges in manufacturing cost efficiency and compatibility with varying cable diameters, especially in high-speed data connections where cross-talk interference is a concern, and there is a need for both shielded and unshielded cable solutions.
Innovation Solution
The electrical connector features a metal ferrule with a sleeve-like holding portion and crimping wings, allowing for form-fitting connection to a terminal body, which can be crimped onto cables of different diameters, providing secure attachment and resistance to axial movement, and includes a lug for locking and polarization features to ensure proper orientation and fit within the terminal body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a ferrule is used to accommodate cables of different diameters, then the adaptability of the connector is improved, but the manufacturing precision and secure attachment may deteriorate
Solution Approach 1:
The ferrule incorporates a crimping portion with crimping wings that can be deformed to different degrees to accommodate cables of different diameters. The holding portion maintains a standardized form-fitting design for precise connection to the terminal body. This local differentiation allows the ferrule to adapt to varying cable sizes while maintaining manufacturing precision in the connection interface.
Solution Approach 2:
The crimping wings of the ferrule are designed to be deformable during the crimping process, allowing dynamic adjustment to fit cables of different diameters. This dynamic characteristic enables the ferrule to adapt to varying cable sizes while the holding portion maintains a fixed, precise form for connection to the terminal body.
2Device complexity
If a ferrule is pressed into a terminal body without additional locking mechanisms, then the device complexity is reduced, but the reliability of the connection deteriorates
Solution Approach 1:
The ferrule is divided into functionally distinct segments: a holding portion for form-fitting connection to the terminal body and a crimping portion for attachment to the cable. This segmentation allows each part to perform its specific function optimally, with the holding portion providing reliable anchoring through its form-fitting design while the crimping portion secures the cable attachment.
Solution Approach 2:
The holding portion of the ferrule is designed to be nested within the terminal body in a form-fitting manner, creating a reliable connection through the interference fit between the ferrule's outer surface and the terminal body's receptacle. This nested arrangement provides secure attachment without additional locking mechanisms.
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
This solution enables cost-effective manufacturing of electrical connectors that can accommodate various cable diameters, ensuring reliable high-speed data transmission with reduced cross-talk interference, suitable for both shielded and unshielded cables, and provides high pull-out force resistance.
Implementation Method 1
The ferrule (3) is made of metal in order to enable the ferrule to be crimped onto the outer insulation of the cable
Implementation Method 2
The ferrule (3) is provided with a lug (16) which projects from an outer circumferential face of the ferrule (3) in a radial direction into a locking opening (17) of the terminal body (1)
Implementation Method 3
The ferrule has a sleeve like holding portion centering the ferrule within the receptacle
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Electrical connector comprising: a terminal body 1; an insulator 2 accommodated within a receptacle 11 of the terminal body 1, said insulator 2 having at least one cavity 7 adapted for holding a terminal connected to a wire 8 of a cable 9; a metal ferrule 3 accommodated within said receptacle 11 of said terminal body 1; wherein said metal ferrule 3 has a crimp portion 29 adapted to be crimped onto said cable 9 and that said metal ferrule 3 is form-fittingly connected to said terminal body 1.