RF Cable Connector Crimping Method for Automated Assembly

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Solution Overview

Problem

Conventional RF cable end connector jumpers require soldering techniques for bonding, which hinders automatic production processes and increases fabrication costs due to the difficulty in fixing relative positions of central and outer conductor terminals.

Innovation Solution

An internal terminal with a composite structure integrated with an insulator by embedded molding, featuring clamps for central and outer conductors, and a casing terminal contact, allowing for clamping and automatic connection of coaxial cables, thereby fixing terminal positions and enabling fully automatic processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering technique is used for bonding RF cable end connector and coaxial cable, then reliable electrical connection is achieved, but automatic production is hindered and fabrication cost increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidproduction automation capability

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The patent replaces the soldering process (thermal/mechanical system) with a crimping mechanism (purely mechanical system). The crimping tool applies controlled mechanical force to deform the connector's metal housing and internally mounted terminals, creating reliable electrical connections without requiring soldering equipment or thermal processes, thereby enabling full automation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The internal terminals (central conductor terminal and outer conductor terminal) are pre-mounted and fixed within the metal housing before the crimping operation. This preliminary arrangement ensures that when crimping occurs, the terminals are already positioned to make proper contact with the coaxial cable conductors, eliminating the need for complex alignment during automated production.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If soldering technique is used for bonding, then electrical connection is achieved, but fabrication cost increases due to inability to perform fully automatic processes

Engineering Contradiction:

Improvebonding reliabilityVSAvoidfabrication cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the bonding mechanism from thermal-based (soldering) to mechanical-based (crimping). By altering the fundamental parameter of the bonding process from temperature-dependent to force-dependent, the system achieves both reliable connections and compatibility with automated cost-effective manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If central conductor terminal and outer conductor terminal are separately provided, then connector design flexibility is improved, but difficulty in fixing relative positions increases

Engineering Contradiction:

Improveconnector design flexibilityVSAvoidterminal position alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent combines the central conductor terminal and outer conductor terminal within a single metal housing structure. The housing acts as a unified component that mechanically constrains both terminals, ensuring their relative positions are automatically maintained during assembly. This merging approach preserves design flexibility while eliminating alignment difficulties.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The metal housing serves as an intermediary structure that holds and positions both the central conductor terminal and outer conductor terminal. This intermediary component provides a rigid framework that automatically maintains the precise relative positioning of the terminals, eliminating the need for separate alignment operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10135203B2Connection method of RF cable end connector and coaxial cable and internal terminal used thereof

Publication Date: 2018.11.20 HARUMOTO TECHNOLOGY (SHEN ZHEN) CO LTD

AI summary

A connection method of an RF cable end connector and a coaxial cable and an internal terminal used thereof are provided. An insulator is formed outside a body of the internal terminal by embedded molding, making the internal terminal have a composite structure integrated with the insulator. The internal terminal can be connected to the coaxial cable by, for example, clamping. This allows connection between the RF cable end connector and the coaxial cable to be easily accomplished by automatic processes, thereby reducing fabrication costs of RF cable end connector jumpers.