Flat-Termination Cable Wire for Impedance and Joint Strength
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Solution Overview
Problem
Existing cable wires lack effective impedance control and joint strength at the terminating end, particularly in applications requiring precise electrical connections.
Innovation Solution
The cable wire design features a center conductor with a terminating end that has opposing flat surfaces, including a top flat surface and a bottom flat surface, with specific geometric configurations to enhance impedance control and joint strength, and is enclosed by an insulator that exposes this terminating end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cylindrical portion with taper is used for the terminating end, then the manufacturing process is simplified through heating and pulling, but the impedance control and joint strength are insufficient
Solution Approach 1:
The patent applies local quality by creating distinct geometric zones along the center conductor: a cylindrical portion for general structural integrity, a tapered portion for gradual impedance transition, and a flattened portion for precise impedance control and joint strength. Each zone serves a specific functional purpose, with the flattened portion specifically engineered to provide the required electrical characteristics while maintaining ease of manufacture through the overall drawing process.
2Shape
If the terminating end is tapered to a smaller diameter, then the end geometry is simplified, but the impedance control precision deteriorates
Solution Approach 1:
The patent employs asymmetry by transitioning from a symmetric cylindrical shape to an asymmetric flattened shape at the terminating end. The flattened portion creates an asymmetric cross-section that provides precise impedance control while the overall tapered structure maintains geometric simplicity. This asymmetric termination geometry allows for better electrical performance without significantly complicating the manufacturing process.
Data Source
AI summary
A cable wire includes a center conductor having a terminating end and an insulator enclosing the center conductor while exposing the terminating end, wherein the terminating end has a top flat surface and an opposite bottom flat surface.