HF Connector Crimping for Target Impedance Across Cable Types
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Solution Overview
Problem
Conventional HF-connectors face challenges in maintaining signal integrity due to varying cable diameters and mechanical properties, requiring multiple ferrules for different cable types, which complicates manufacturing and achieves an ideal fit.
Innovation Solution
A method for crimp mounting an HF-crimp connecting device that involves crimping a ferrule with a variable diameter over an exposed shielding conductor, followed by crimping a terminal onto the inner conductor and a shielding contact sleeve, with the crimping dimensions set to achieve a target impedance range using a specific crimping tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional ferrules are used for different cable types, then each cable type can be accommodated, but the number of ferrule types increases and manufacturing complexity increases
Solution Approach 1:
The patent applies universality by designing a single ferrule type that can accommodate multiple cable types through variable crimping dimensions. The ferrule is configured with adjustable geometric parameters (such as crimp depth, crimp width, and ferrule length) that allow it to work with different cable diameters and mechanical properties, eliminating the need for multiple specialized ferrule types while maintaining compatibility across various cable specifications.
Solution Approach 2:
The patent employs parameter changes by modifying the geometric dimensions of the ferrule and crimping parameters (crimp force, crimp depth, crimp width) to adapt to different cable types. By varying these parameters within controlled ranges, the same ferrule design can achieve proper mechanical and electrical connection for different cable configurations, thereby reducing the number of ferrule types needed.
2Adaptability or versatility
If multiple ferrule types are used for varying cable characteristics, then different cable types can be accommodated, but inventory requirements increase and manufacturing becomes more difficult
Solution Approach 1:
The patent implements universality by creating a standardized ferrule design that serves multiple cable types. This single ferrule type incorporates adjustable parameters that allow it to adapt to different cable characteristics (diameter, material properties, shielding configurations), thereby simplifying inventory management and manufacturing processes while maintaining the ability to accommodate varying cable specifications.
Solution Approach 2:
The patent utilizes parameter changes by establishing controllable ranges for ferrule dimensions and crimping parameters. By adjusting these parameters (such as crimp depth, ferrule length, and wall thickness) within specified tolerances, the manufacturing process can accommodate different cable types using the same ferrule design, thus simplifying production while maintaining adaptability to various cable characteristics.
3Stability of the object's composition
If cable diameter varies during connectorization, then mechanical properties cause dimensional changes, but achieving ideal fit becomes difficult
Solution Approach 1:
The patent applies parameter changes by defining controlled ranges for cable diameter and corresponding ferrule dimensions. Instead of requiring exact dimensional matches, the system allows for parameter variations within specified tolerances. The crimping parameters (force, depth, width) are also adjusted within ranges to compensate for cable diameter variations, ensuring consistent connection quality and ideal fit across different cable batches while accounting for mechanical property variations.
Solution Approach 2:
The patent employs preliminary action by pre-configuring the ferrule with adjustable geometric parameters before the crimping process. The ferrule design includes features that can be adjusted to match the specific cable diameter being connected. This preliminary configuration, combined with controlled parameter ranges, allows the system to compensate for cable diameter variations and achieve ideal fit without requiring precise dimensional control during the actual connectorization process.
Data Source
AI summary
A method for crimp mounting a high-frequency (HF) electrical crimp connecting device to an electrical cable includes the steps of crimping a ferrule into a mounting state wherein its maximum diameter is fixed, and arranging the ferrule in its mounting state over an exposed shielding conductor of the cable. A terminal is crimped onto an inner conductor of the cable, and a shielding contact sleeve is placed over the cable and crimped, at least in the area of the ferrule. A target impedance or impedance range of the resulting cable is set according to at least one of a dimension of at least one crimping tool used to perform the crimping steps, or at least one dimension of at least one of the resulting crimps performed by the at least one crimping tool.