Overmolded Coaxial Cable Connector Eliminates Soldering
Solution Overview
Problem
Existing audio signal cables require tedious and costly crimping or soldering processes for connector attachment, leading to potential connectivity issues and increased manufacturing costs.
Innovation Solution
A coaxial audio signal cable assembly using four plug parts held together by an insulating overmold material, eliminating the need for crimping or soldering, and enabling automated manufacturing with solid, permanent connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimping or soldering processes are used for connector attachment, then reliable electrical connections can be achieved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent extracts and eliminates the crimping and soldering operations from the manufacturing process. Instead of using these complex joining methods, the invention uses a simplified insertion and overmolding process where connectors are simply inserted into the cable assembly and then encapsulated by injection-molded material, removing the need for specialized crimping or soldering equipment and operations.
Solution Approach 2:
The patent replaces the mechanical crimping system and thermal soldering system with a purely mechanical insertion system combined with injection molding. The connectors are inserted into position and then secured by molten overmold material that encapsulates them, substituting complex mechanical joining processes with a simpler molding operation.
2Strength
If crimping or soldering operations are performed, then durable connector connections are achieved, but manufacturing time and labor costs increase
Solution Approach 1:
The patent merges the connector attachment operation with the overmold manufacturing operation into a single integrated process. The connectors are inserted into the cable assembly, and then the overmold material is injected to simultaneously secure the connectors and form the protective outer mold, combining what would traditionally be separate operations into one efficient manufacturing step.
Solution Approach 2:
The patent performs preliminary insertion of connectors into the cable assembly before the overmolding operation. This preliminary positioning ensures that connectors are correctly placed and aligned before the overmold material is injected, allowing the subsequent molding operation to simply encapsulate and secure them without requiring additional adjustment or processing steps.
3Ease of operation
If traditional plug assemblies with multiple parts are used, then connector functionality is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent segments the plug assembly into distinct functional components (connectors, cable, overmold) that can be independently manufactured and then assembled through a simple insertion and molding process. This segmentation allows each component to be optimized separately while simplifying the overall manufacturing process compared to traditional multi-part assemblies requiring complex fastening operations.
Data Source
AI summary
A signal cable comprising a plurality of plug parts forming a plug that is operatively connected to signal and ground conductors at one end of a coaxial cable, wherein the plug parts and the end of the coaxial cable are held together only by an insulating overmold material. The assembly has four operatively connected plug parts (12, 20, 24, 30); a signal conductor at one end (42) of a coaxial cable (40) conductively connected to one of the plug parts (12); and an overmold (54) encapsulating the end of the cable and a conductive connection between a cable ground sleeve and another plug part (30).