Outer Conductor Crimp Structure With Interlocking Flanks
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Solution Overview
Problem
The existing crimp connections between the outer conductor of an electrical cable and the outer conductor contact element in electrical connectors are prone to breaking due to air gaps formed during the crimping process, which compromises the mechanical stability and form fit between the crimping flanks.
Innovation Solution
The outer conductor contact element features finger-shaped extensions and recesses on its crimping flanks, which interlock in a specific directional configuration to eliminate air gaps and enhance the form fit, ensuring a stable crimp connection by aligning the side edges without gaps and utilizing chamfers to prevent wire escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimp connections are used without interlocking features, then the manufacturing process is simple, but air gaps form during crimping causing the connection to break and mechanical stability deteriorates
Solution Approach 1:
The crimping structure is segmented into two separate crimping flanks with distinct interlocking features (protrusions and recesses). This segmentation allows each flank to be optimized independently while working together to eliminate air gaps and prevent connection failure during crimping.
Solution Approach 2:
One crimping flank features protrusions that fit into corresponding recesses on the other flank, creating a nested interlocking configuration. This nesting eliminates air gaps between flanks during crimping, preventing the connection from breaking while maintaining mechanical stability.
2Strength
If crimping flanks are pressed together during crimping, then the crimp connection is formed, but impact forces cause deformation and air gaps form between side edges
Solution Approach 1:
The crimping flanks are designed with asymmetric interlocking features where protrusions on one flank correspond to recesses on the other. This asymmetric design ensures that during crimping, the features guide and constrain the flanks, maintaining precise alignment of side edges even under impact forces, thereby preventing air gap formation.
3Reliability
If the outer conductor is folded back around the support sleeve, then the crimp connection is created, but the connection may break under elastic pressure from the support sleeve
Solution Approach 1:
The interlocking features (protrusions and recesses) are pre-formed on the crimping flanks before the crimping process. This preliminary preparation ensures that when the outer conductor is folded back and crimped, the interlocking features are already in position to prevent breaking under elastic pressure from the support sleeve, while maintaining ease of assembly.
Data Source
AI summary
An outer conductor contact element for an electrical connector assembly has a first crimping portion for crimping an outer conductor of an electrical cable inserted inside the outer conductor contact element to the outer conductor contact element. The first crimping portion has two opposing crimping flanks, which fully circumferentially crimp the outer conductor in a final assembly state. In the final assembly state, a finger-shaped extension is formed on a side edge of one crimping flank and a corresponding finger-shaped recess is formed on a side edge of the other crimping flank, into which the finger-shaped extension is engaged. The finger-shaped extension and the finger-shaped recess each have at least one longitudinal extension portion with a directional component in a longitudinal axial direction L of the outer conductor contact element and with a directional component transverse to the longitudinal axial direction L.