Shielded Cable Connector Crimp Wings Knurl Pattern
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Solution Overview
Problem
There is a need for a wire cable that can transmit high data rate signals efficiently while being flexible, lightweight, and cost-effective, suitable for automotive and other applications, as existing fiber optic cables are fragile and expensive, and twisted pair cables with shielding are not adequately meeting these requirements.
Innovation Solution
A shielded wire cable assembly with a conductive wire pair and a braided conductor, encased in dielectric belting to maintain consistent radial distance and twist lay length, providing controlled impedance and immunity to electromagnetic interference, along with a connector system that includes crimp wings and a knurl pattern for secure attachment and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If fiber optic cable is used to achieve high data transfer rates and electromagnetic interference immunity, then data transfer rate and EMI resistance are improved, but cost and fragility worsen
Solution Approach 1:
The patent replaces expensive fiber optic cable with a cost-effective twisted pair cable assembly that achieves comparable high-speed data transmission (up to 10 Gb/s) through optimized cable construction and connector design, making the system more economical while maintaining reliability
2Speed
If fiber optic cable is used to achieve high data transfer rates and electromagnetic interference immunity, then data transfer rate and EMI resistance are improved, but cost worsens
Solution Approach 1:
The patent uses inexpensive twisted pair cable and connector components instead of expensive fiber optic infrastructure, achieving high-speed data transmission through optimized cable construction with controlled impedance and proper shielding, thereby reducing overall system cost
Solution Approach 2:
The patent optimizes cable parameters including impedance control (100 ohms differential), twist lay length, and conductor geometry to enable twisted pair cable to achieve 10 Gb/s transmission rates, previously the domain of fiber optic cable, thus providing a cost-effective alternative
3Object-affected harmful factors
If shielded twisted pair cable is used to achieve electromagnetic interference resistance, then EMI resistance is improved, but mass worsens
Solution Approach 1:
The patent applies shielding selectively - using individual pair shielding for pairs requiring EMI protection while leaving other pairs unshielded, and using foil shielding only where necessary, thereby reducing overall cable mass while maintaining EMI resistance for critical signal pairs
4Reliability
If conventional cable assembly methods are used to achieve secure connection, then connection reliability is improved, but manufacturing complexity worsens
Solution Approach 1:
The patent integrates the connector shield directly with the cable shield through a unified crimping process, eliminating separate assembly steps for attaching connector shields and cable shields, thereby simplifying manufacturing while ensuring reliable electrical and mechanical connection
Solution Approach 2:
The connector design incorporates self-aligning and self-securing features where the crimp wings automatically engage with the cable shield and the connector body self-adjusts during assembly, reducing the need for complex alignment procedures and specialized tooling
Data Source
AI summary
An electrical shield connector configured to be attached to an end of a shielded cable having a conductive wire and a shield conductor longitudinally surrounding the conductive wire. The shield connector includes a connection portion that is configured for connection with a corresponding mating electrical shield connector and a cable attachment portion that is configured to longitudinally receive an end of the shield conductor. The connection portion defines a shroud surrounding an electrical terminal attached to the conductive wire. The cable attachment portion and/or crimp wings projecting therefrom define a projection that is configured to contact and indent the shield conductor, thereby mechanically and electrically connecting the shield connector to the shield conductor. The cable attachment portion may also define a knurled pattern in an interior surface of the cable attachment portion, such as a knurled pattern having a number of rhomboid-shaped indentations.