Seamless Cylindrical Cable Connector for RF Leakage Control
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Solution Overview
Problem
Traditional automotive FAKRA interconnection systems are unable to meet the increasing demands for more transmission channels and higher frequencies required by advanced vehicle technologies such as 360-degree surround view, fatigue driving, 5G communication, GPS, and vehicle-to-machine communication. These systems occupy more space and incur higher costs, and they suffer from issues like poor fit with docking connectors and radio frequency leakage.
Innovation Solution
A cable connector design featuring an insulative seat, external terminals with a seamless hollow cylindrical structure, central terminals, and insulators, which improve structural strength and high-frequency data transmission quality. The external terminals are supported by the insulating seat, ensuring stable contact and positional accuracy with docking connectors, and the seamless structure addresses radio frequency leakage issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional stamped ring structure is used for external terminal, then manufacturing is easier, but radio frequency leakage occurs at joint line and external dimensional tolerance is large
Solution Approach 1:
The patent changes the structural parameters of the external terminal from a stamped ring structure to a seamless cylindrical structure. This parameter change eliminates the joint line where RF leakage occurs, while maintaining manufacturability through processes like drawing or rolling. The seamless structure provides continuous RF shielding without compromising manufacturing ease.
Solution Approach 2:
The external terminal is constructed as a composite structure with a seamless cylindrical body made of conductive material, providing both structural integrity and RF shielding. The integration of the insulator within this seamless structure creates a composite assembly that prevents RF leakage while maintaining ease of manufacture through standardized production processes.
2Ease of manufacture
If traditional stamped ring structure is used for external terminal, then manufacturing is easier, but external dimensional tolerance is large causing poor fit with docking connector
Solution Approach 1:
The patent changes the external terminal from a stamped ring structure to a seamless cylindrical structure, which inherently provides better dimensional control. The seamless construction method (drawing or rolling) produces more consistent external dimensions and smaller tolerances, ensuring proper fit with docking connectors while remaining manufacturable through established processes.
3Reliability
If traditional FAKRA interconnection system is used, then current requirements are met, but space occupation increases and cost increases for future high-frequency applications
Solution Approach 1:
The patent changes the structural parameters of the connector components, particularly the seamless cylindrical external terminal and integrated insulator design, which reduce overall connector volume. These parameter changes enable the system to support higher frequencies (beyond traditional FAKRA capabilities) while occupying less space, eliminating the need for larger connectors required by older designs.
4Reliability
If traditional FAKRA interconnection system is used, then current requirements are met, but cost increases for future high-frequency applications
Solution Approach 1:
The patent changes the manufacturing approach by adopting seamless cylindrical structures that can be produced through efficient processes like drawing or rolling. These parameter changes enable mass production with lower costs compared to traditional stamped and assembled ring structures, making high-frequency connectors more cost-effective for future automotive applications.
Data Source
AI summary
A cable connector, includes an insulative seat, at least one external terminal, at least one insulator inserted and fixed inside the external terminal, at least one central terminal inserted and fixed in the insulator and at least one cable. The external terminal includes an outer contacting portion located at the front end and an outer connecting portion located at the rear end, the central terminal includes a central connecting portion located at the rear end, the cable includes a conductor, an insulating layer wrapping around the conductor and a metal braided layer, the central connecting portion is connected to the conductor, and the outer connecting portion is connected to the braided layer, wherein the external terminal is provided with a seamless hollow cylindrical structure, and the insulator is placed inside the hollow cylindrical structure, and the hollow cylindrical structure is supported on the insulating seat.