Shielded Connector Structure With Inward Projections for Impedance Control
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Solution Overview
Problem
Existing connector structures face processing distortions and potential cracks in the outer conductor due to excessive drawing, leading to enlarged designs that fail to suppress changes in characteristic impedance effectively.
Innovation Solution
A connector structure with a shielded cable configuration where the outer conductor has projecting portions formed by folding inward, allowing the inner surface to be closer to the coated wire without enlarging the conductor, and crimping methods are used to connect components without heat, reducing manufacturing costs and preventing dielectric issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the outer conductor is drawn inwardly to reduce distance to the coated wire, then the characteristic impedance change is suppressed, but processing distortion occurs and cracks may form in the outer conductor
Solution Approach 1:
The outer conductor is divided into multiple sections: a first outer conductor portion that is drawn inward to reduce distance to the coated wire, and a second outer conductor portion that maintains the original distance. This segmentation allows the drawing operation to be localized, suppressing characteristic impedance change in the critical region while preventing excessive processing distortion and crack formation in the overall conductor structure.
2Reliability
If the front-rear length of the outer conductor to be drawn is increased to suppress processing distortion, then the outer conductor integrity is maintained, but the connector structure is enlarged
Solution Approach 1:
The drawing operation is applied locally only to a specific first portion of the outer conductor where the coated wire is exposed, rather than drawing the entire outer conductor. This localized approach maintains outer conductor integrity by limiting the drawn length, while still achieving the necessary distance reduction to suppress characteristic impedance change, thereby preventing connector structure enlargement.
3Strength
If heat is used to connect components, then the connection strength is improved, but heat-related troubles occur in the dielectric
Solution Approach 1:
The patent replaces thermal connection methods with mechanical crimping connection. The crimping connection mechanically secures the inner conductor to the coated wire and the outer conductor to the shield portion without applying heat, thereby maintaining connection strength while avoiding heat-related damage to the dielectric material.
Data Source
AI summary
A female connector structure is provided with a shielded cable configured such that an outer periphery of a coated wire including a core and an insulation coating is surrounded by a braided wire, a female terminal including a wire barrel and a connecting tube portion and to be connected to a mating terminal, an insulating dielectric for surrounding an outer periphery of the connecting tube portion, and an outer conductor including a shield connecting portion, the outer conductor surrounding at least the coated wire. A part of the outer conductor corresponding to the coated wire exposed from the braided wire is formed with a projecting portion by causing a part of an inner surface of the outer conductor to project from other parts radially inwardly of the outer conductor, and an outer surface of the outer conductor is not depressed radially inwardly of the outer conductor.