Polymer Strain Relief for Coaxial Cable Interconnection
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Solution Overview
Problem
Coaxial cable and connector interconnections using aluminum outer conductors face strength deficiencies and issues with flux residue and moisture ingress, leading to corrosion and reduced reliability.
Innovation Solution
A strain relief is created through low-pressure injection molding of a polymer material around the interconnection, encapsulating the solder joint and flux residue, and providing a reinforced seal and strength enhancement with a tapered and grooved design that anchors to the connector body and extends over the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum material is used for the outer conductor, then material cost and weight are reduced, but strength and bending resilience are reduced
Solution Approach 1:
The patent employs a composite structure where the aluminum outer conductor is combined with a polymer strain relief material. The aluminum provides weight savings and cost benefits, while the polymer composite material compensates for the reduced strength and bending resilience of aluminum, creating a hybrid system that achieves both lightweight construction and mechanical durability.
2Ease of manufacture
If soldering is used to interconnect cable and connector, then a cost-effective electro-mechanical interconnection is achieved, but flux residue and corrosion issues arise
Solution Approach 1:
The patent extracts and removes the harmful flux residue from the interconnection area through the polymer strain relief material. The polymer is molded to encapsulate the solder joint, physically separating and containing the flux residue away from the critical electrical connection, thereby maintaining manufacturing simplicity while eliminating corrosion risks and improving long-term reliability.
Solution Approach 2:
The polymer strain relief material acts as an intermediary barrier between the flux residue and the solder joint. This intermediate layer prevents direct contact between corrosive flux and the electrical connection, allowing soldering to remain the manufacturing method of choice while protecting against its harmful byproducts.
3Shape
If heat shrink tubing is used for strain relief, then cosmetic improvement is achieved, but environmental sealing is insufficient allowing moisture ingress
Solution Approach 1:
The patent merges multiple functions into a single polymer strain relief component: mechanical strain relief, environmental sealing, and flux residue containment. Unlike heat shrink tubing that only provides cosmetic improvement and limited strain relief, this integrated polymer structure simultaneously addresses appearance, mechanical support, and creates a hermetic seal against moisture and environmental contaminants.
Solution Approach 2:
The polymer strain relief material combines the cosmetic benefits of heat shrink tubing with enhanced environmental sealing properties. The composite polymer structure provides both the aesthetic finish and the moisture barrier necessary to protect the interconnection, eliminating the inadequacies of conventional heat shrink tubing.
4Quantity of substance
If aluminum outer conductor is used, then material cost is reduced, but flux residue corrosion and moisture ingress occur
Solution Approach 1:
The polymer strain relief material serves as an intermediary protective layer that shields the aluminum outer conductor from harmful flux residue and moisture. This intermediate barrier prevents direct exposure of the aluminum to corrosive elements, maintaining cost-effectiveness while eliminating corrosion and moisture ingress issues.
Solution Approach 2:
The polymer structure extracts and isolates the flux residue from the aluminum outer conductor through encapsulation. By physically removing and containing the harmful flux away from the aluminum surface, the patent prevents corrosion while maintaining the cost advantages of aluminum construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly enhances the strength and environmental seal of the interconnection, reducing corrosion and buckling risks while enabling the use of aluminum materials for cost savings, and also improves flexibility and reliability for copper-based cables.
Implementation Method 1
A strain relief is created through low-pressure injection molding of a polymer material around the interconnection
Data Source
AI summary
A strain relief for a coaxial cable and coaxial connector interconnection is provided as an injection moldable polymer material surrounding the interconnection. The injection moldable material fills a solder pre-form cavity between an outer conductor of the coaxial cable and an inner diameter of a bore of the connector body, strengthening and environmentally sealing the interconnection. Where the outer conductor is corrugated, the polymer material may be provided covering an exposed portion of the corrugations and/or filling portions of a corrugation trough between an outer jacket and the outer diameter of the outer conductor.