Overlapping Barrel Terminal for Coaxial Cable Shield Stability
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Solution Overview
Problem
In coaxial cables, the separation distance between the core and shield layer changes under tensile load, leading to reduced high-frequency characteristics due to shifting of barrel pieces crimped to the shield layer, necessitating a stronger fixing force that can maintain uniform crimping without deforming the inner insulating layer.
Innovation Solution
The use of first and second opposed barrel pieces crimped in an overlapping state to the shield layer, with an engaging protrusion on one barrel piece and an engaging hole on the other, maintains the crimped position even under tensile force, ensuring a uniform circumferential force and preventing shifting, thus maintaining constant separation distance and high-frequency characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If barrel pieces are crimped with strong fixing force to prevent shifting under tensile load, then reliability of connection is improved, but the inner insulating layer may be deformed and high frequency characteristic deteriorates
Solution Approach 1:
The terminal is divided into multiple barrel pieces (first barrel piece and second barrel piece) that are crimped in an overlapping state. This segmentation allows the fixing force to be distributed across multiple components, preventing any single barrel piece from deforming the inner insulating layer while collectively providing strong fixation against tensile loads.
Solution Approach 2:
The first and second barrel pieces are arranged in an overlapping nested configuration, where one barrel piece partially overlaps the other. This nesting structure enables both barrel pieces to share the fixing force, maintaining connection reliability without concentrating excessive force on the shield layer or inner insulating layer.
2Manufacturing precision
If barrel pieces are crimped with uniform force in circumferential direction, then manufacturing precision is improved, but fixing force under tensile load is reduced
Solution Approach 1:
By segmenting the terminal into multiple barrel pieces crimped in an overlapping state, the invention achieves both uniform circumferential crimping (each barrel piece crimps uniformly) and strong overall fixing force (multiple pieces working together). The overlapping configuration ensures that uniform crimping of individual pieces translates to uniform overall fixation.
Solution Approach 2:
The first and second barrel pieces are combined in an overlapping configuration, merging their individual fixing forces into a unified strong connection. This combination allows the terminal to achieve both uniform crimping (from each piece) and strong overall fixing force (from the merged structure).
3Ease of operation
If tip sides of barrel pieces are allowed to shift under tensile load, then ease of operation is improved, but separation distance changes and high frequency characteristic deteriorates
Solution Approach 1:
The segmented barrel piece structure with overlapping configuration provides inherent flexibility during crimping operations, allowing easy installation. Once crimped, the overlapping structure prevents relative shifting between barrel pieces under tensile load, thereby maintaining uniform separation distance between the core and shield layer.
4Reliability
If stronger fixing force is applied to prevent barrel piece shifting, then reliability is improved, but the inner insulating layer is deformed
Solution Approach 1:
Dividing the terminal into multiple barrel pieces distributes the fixing force across several contact points, preventing any single point from exerting excessive force that would deform the inner insulating layer. The segmented structure achieves strong overall fixation without localized stress concentration.
Solution Approach 2:
The nested overlapping configuration of barrel pieces allows them to share the fixing force, reducing the force exerted on the inner insulating layer by any single barrel piece while maintaining strong overall connection reliability.
Data Source
AI summary
A cable with terminal includes a coaxial cable in which a core, an inner insulating layer, a shield layer and an outer insulating layer are concentrically arranged from an inner side to an outer side, and a terminal connected to the coaxial cable. The terminal includes a pair of barrel pieces crimped in an overlapping state to an exposed part of the shield layer. An engaging protrusion is provided on the barrel piece on one side out of the pair of barrel pieces and projects toward the barrel piece on the other side. The engaging protrusion is engaged with a hole edge part of an engaging hole provided in the barrel piece on the other side.