HF Coaxial Cable Angular Connection Cold Forming
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Solution Overview
Problem
Existing HF coaxial angular plug connections face challenges in reducing production costs and complexity, while maintaining high-frequency signal transmission quality, especially at frequencies above 4 GHz, due to large overall heights and complex installation processes.
Innovation Solution
A HF coaxial cable with a corrugated metal outer conductor and a dielectric layer, featuring a bending radius significantly smaller than the manufacturer's minimum specification, allowing for cold forming to maintain impedance and reduce overall height, combined with a straight plug connector for simplified assembly and improved signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cable is bent with a small bending radius to achieve compact angular plug connection, then the overall height is reduced, but the wave impedance changes and signal transmission quality deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the bending radius to be smaller than conventional values, while compensating for impedance changes through specific geometric parameters of the bend region. The bending radius r is chosen in the range of 0.5 to 2 times the outer conductor diameter d, which is smaller than conventional bending radii, achieving compact size while maintaining impedance through optimized geometry.
Solution Approach 2:
The patent applies local quality by creating a specific bend region with differentiated properties from the rest of the cable. The bend region has a controlled bending radius and specific geometric characteristics that differ from the straight cable sections, allowing localized adaptation to maintain overall signal transmission quality while achieving compact angular connection.
2Strength
If a corrugated outer conductor is used to maintain structural integrity during bending, then mechanical strength is improved, but production complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the corrugation geometry parameters, specifically the corrugation depth and spacing, to achieve the right balance between mechanical strength during bending and ease of manufacturing. The corrugated structure provides necessary mechanical reinforcement while remaining compatible with standard manufacturing processes for coaxial cables.
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 achieves compact angular plug connections with enhanced high-frequency signal transmission qualities, comparable to undeformed cables, while reducing production complexity and costs, and is applicable to various standardized diameter classes.
Implementation Method 1
cold forming to maintain impedance and reduce overall height
Data Source
AI summary
The invention is characterized in that a HF coaxial cable is designed as a conventional corrugated sheath cable comprising a cable outer conductor, in the form of a metal corrugated tube, having a line impedance Zk and a minimum bending radius rk,min specified by the manufacturer as a characteristic feature of the coaxial cable; in corrugated sheath cable, directly or indirectly following the straight plug connector, is bent to have a bending radius rα, where 0.2 rk,min≦rα≦0.9 rk,min, which alters the line impedance Zk by a maximum of 1 ohm. The bend with the bending radius rα is produced by cold forming corrugated sheath cable with the introduction of bending forces and tensile forces directed along said corrugated sheath cable.