Outer Conductor Crimp Flank Interlock to Eliminate Air Gaps
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Solution Overview
Problem
The existing crimp connection between the outer conductor of an electrical cable and the crimp sleeve in electrical connectors is prone to air gaps due to deformation, leading to a weakened mechanical connection and easier breakage under radial pressure.
Innovation Solution
The design incorporates finger-shaped extensions and recesses on the crimping flanks, which interlock in the final assembly state, eliminating air gaps and providing a stable, positive connection by transferring impact forces perpendicular to the undercut areas, ensuring optimal contact resistance and preventing crimp connection breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crimp flanks are pressed together during crimping, then the crimp connection is formed, but air gaps appear between the side edges due to deformation
Solution Approach 1:
The finger-shaped extensions and recesses are pre-formed on the crimp flanks before the crimping process. These interlocking features are designed in advance to compensate for deformation that will occur during crimping, ensuring that the side edges remain in positive contact without air gaps even after the crimping forces are applied.
Solution Approach 2:
The solution introduces a new geometric dimension by adding finger-shaped extensions that protrude from one crimp flank and corresponding recesses on the opposing flank. This creates an interlocking mechanism in the transverse direction that prevents separation in the longitudinal direction, effectively eliminating air gaps through a dimensional approach rather than simply increasing crimping force.
2Ease of manufacture
If the crimp connection is made with conventional crimp flanks, then the manufacturing is simple, but the mechanical stability is reduced under radial pressure
Solution Approach 1:
The crimp flanks are segmented with finger-shaped extensions and recesses that create discrete interlocking points. This segmentation allows the connection to maintain stability under radial pressure by distributing the forces across multiple contact points rather than relying on a continuous surface, while still being manufacturable using standard stamping and bending techniques.
Solution Approach 2:
The finger-shaped extensions on one crimp flank are designed to mate with recesses on the opposing flank, creating an asymmetric interlocking geometry. This asymmetric design provides directional stability that resists radial pressure forces, while the overall manufacturing process remains symmetric and simple, maintaining ease of production.
3Force
If the crimp flanks are deformed during crimping, then the crimp connection is secured, but the undercuts are damaged and air gaps form
Solution Approach 1:
The finger-shaped extensions and recesses are pre-formed with adequate material thickness and structural integrity before crimping. This preliminary preparation ensures that the undercuts can withstand the deformation forces applied during crimping without collapsing or creating air gaps, as the interlocking geometry is already established to guide the deformation process.
Solution Approach 2:
The design incorporates sufficient material volume in the finger-shaped extensions and recesses to act as a cushion against deformation damage. This excess material capacity absorbs the stresses of the crimping process, protecting the undercut structures from damage while still achieving the necessary crimp connection force.
Data Source
Figure 1A~2
Figure 3A~4B
Figure 4C~4F
AI summary
The present invention relates to an external conductor contact element. The present invention further relates to an electrical connector assembly. Finally, the present invention relates to a method for manufacturing the electrical connector assembly. An external conductor contact element (11) for an electrical connector assembly (1) has a first crimp section (13) for crimping an external conductor (6) of a cable (2) inserted within the external conductor contact element (11) to the external conductor contact element (11). The first crimp section (13) has two opposing crimp flanks (16) which fully crimp the external conductor (6) in a final assembly state.In the final assembly state, a finger-shaped extension (20) is formed on a side edge (17) of one crimp flank (16), and a corresponding finger-shaped recess (19) is formed on a side edge (17) of the other crimp flank (16), into which the finger-shaped extension (20) is engaged. The finger-shaped extension (20) and the finger-shaped recess (19) each have at least one longitudinal section with a directional component in a longitudinal axis L of the outer conductor contact element (11) and with a directional component transverse to the longitudinal axis L.