Overmoulded Cable Termination for Solderless Data Connections
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Solution Overview
Problem
Existing subsea connectors require costly and time-consuming soldering processes for cable termination, leading to high assembly costs and potential interference issues due to untwisted cable lengths, which can degrade data transmission quality.
Innovation Solution
A dry-mate cable connection system using an overmoulded cable termination housing that separates electrical conductors at the termination end, allowing for quick and solderless assembly, with a design that minimizes untwisted cable lengths and maintains electrical insulation and screening for reduced interference and improved sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering processes are used for cable termination, then reliable electrical connection is achieved, but assembly cost and time increase significantly
Solution Approach 1:
The patent replaces the soldering process (thermal/mechanical system) with a mechanical insertion system. The cable assembly with conductors is simply inserted into the connector housing, eliminating the need for soldering while maintaining reliable electrical connection through direct contact between conductors and contact elements.
Solution Approach 2:
The connector housing and cable assembly are designed to self-align and self-secure through mechanical features such as guide ribs, positioning elements, and retention mechanisms. The cable conductors automatically make contact with the contact elements upon insertion, eliminating the need for complex assembly procedures.
2Reliability
If soldering processes are used for cable termination, then reliable electrical connection is achieved, but assembly cost increases
Solution Approach 1:
The patent eliminates soldering equipment, skilled soldering labor, and associated materials (solder, flux, cleaning agents) by using a purely mechanical insertion system. This significantly reduces manufacturing costs while maintaining connection reliability through precision-machined contact elements and conductors.
Solution Approach 2:
The invention changes the connection mechanism from thermal bonding (soldering) to mechanical bonding (direct contact). This parameter change in the joining method simplifies the manufacturing process and reduces costs while maintaining adequate mechanical and electrical connection strength.
3Ease of operation
If cable conductors are untwisted for termination, then connection is simplified, but interference issues arise degrading data transmission
Solution Approach 1:
The cable assembly is prepared in advance with conductors positioned and insulated to the correct length before insertion. The insulation ensures that even if conductors are untwisted, they remain electrically isolated from each other, preventing interference while allowing simple termination.
Solution Approach 2:
The patent introduces an insulating barrier (insulation layer or insulation elements within the connector) as an intermediary between adjacent conductors. This prevents electromagnetic interference and crosstalk even when conductors are separated from their twisted configuration, maintaining data transmission quality.
4Volume of moving object
If outer insulating layers of conductors are in contact, then cable structure is compact, but electrical insulation between conductors is compromised at termination end
Solution Approach 1:
The patent segments the cable structure at the termination end by separating the outer insulating layers of individual conductors. This segmentation allows each conductor to be independently positioned and connected while maintaining electrical insulation through the connector housing design, preventing contact between adjacent conductors.
Solution Approach 2:
The cable maintains its compact structure with contacting insulating layers along its length, but at the termination end, the local quality changes to provide separation. The connector housing provides localized insulation and positioning features that ensure electrical isolation only where needed for reliable connection.
Data Source
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AI summary
A dry mate cable connection (40) comprises a data cable (4). The data cable comprises a plurality of electrical conductors (23) and at least one electrically insulating outer layer (44) surrounding each data conductor, whereby the data conductors (23) are electrically insulated from one another. The cable comprises a termination end. The outer layer (44) of each conductor is physically in contact with an outer layer (44) of an adjacent conductor, except at the termination end. The plurality of electrical conductors (23) at the termination end are physically separated from one another by a single electrically insulating overmoulded cable termination housing (43). The housing is in contact with at least part of the electrically insulating layers (44) of each of the electrical conductors.