Shielded Cable Connector Crimping Mechanism
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Solution Overview
Problem
Existing electric connectors for shielded cables face challenges in maintaining strong connections and assembly integrity, especially under pulling forces, as they often rely on soldering which can crack and reduce workability and longevity.
Innovation Solution
The electric connector assembly kit features a crimping mechanism with a U-shaped barrel contact and a conductive plug shell, where the barrel is press-fitted into a U-shaped slot and pinched by a coupling piece, enhancing connection strength without soldering, and includes a plug cover shell with a coupling piece that hooks onto the plug shell for additional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If soldering is used to connect the outer conductor to the electric connector shell, then connection strength is improved, but workability deteriorates and solder cracking occurs under repeated pulling forces
Solution Approach 1:
The patent replaces the thermal joining method (soldering) with a mechanical joining method (crimping). The barrel contact mechanically crimps the outer conductor through direct pressure, eliminating the need for heat and solder material. This substitution maintains connection strength while dramatically improving workability and eliminating solder cracking issues.
Solution Approach 2:
The patent changes the joining mechanism from thermal-dependent (soldering requires melting point temperature) to mechanical-dependent (crimping requires only sufficient pressing force). This parameter change allows the connection to be made at room temperature with simple tooling, improving ease of manufacture while maintaining reliable connection strength.
2Strength
If soldering is used to enhance connection strength, then connection strength is improved, but product longevity deteriorates due to solder cracking
Solution Approach 1:
The patent replaces the thermal joining method (soldering) with a mechanical joining method (crimping). The barrel contact mechanically crimps the outer conductor through direct pressure, eliminating the need for heat and solder material. This substitution maintains connection strength while dramatically improving workability and eliminating solder cracking issues.
Solution Approach 2:
The patent uses a simple metal barrel contact that can be easily replaced or manufactured, eliminating the need for fragile solder joints. The crimping mechanism creates a robust mechanical connection that is more reliable and longer-lasting than soldered connections under repeated stress.
3Ease of manufacture
If a simple crimping structure is used, then ease of manufacture is improved, but connection strength under pulling forces deteriorates
Solution Approach 1:
The patent divides the connection structure into distinct functional segments: the barrel contact for crimping the outer conductor, the U-shaped slot in the plug shell for receiving and constraining the barrel, and the coupling piece for additional mechanical interlocking. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity and strength.
Solution Approach 2:
The patent employs a composite structure combining the conductive barrel contact (metal) with the insulating plug shell (molded resin). The plug shell is formed as a composite of resin material incorporating reinforcing fibers or a fiber-reinforced resin composition, providing both electrical insulation and mechanical strength to resist pulling forces while maintaining ease of manufacture through molding.
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
This solution significantly enhances the connection strength and assembly stability of the electric connector and shielded cable against pulling forces, improves shielding, and maintains performance over a long period without the need for soldering, thus improving workability and product longevity.
Implementation Method 1
a conductive barrel contact being fixed to the holder housing and being provided with a barrel being formed substantially into a U-shape when seen in the depth direction on the front side in the depth direction of the wire holding part of the holder housing for crimping the outer conductor
Implementation Method 2
a conductive plate-shaped plug cover shell having a coupling piece having a width substantially corresponding to the part between the U-shaped slots in the supporting piece of the plug shell and extending from the front side in the depth direction toward the lower side
Implementation Method 3
an outer conductor covering the inner wire, and an outer insulating coating covering the outer conductor
Data Source
AI summary
The electric connector assembly kit is structured that the inner wire of the end of the shielded cable is fitted and held in the wire holding part of the wire holder and the outer conductor is crimped by the barrel, the connector body is set on the lower side of the wire holder, the inner conductor of the inner wire is connected to the contact and the barrel is press-fitted in the U-shaped slot, the plug cover shell is set on the higher side of the wire holder and made to contact the barrel, and the top end of the coupling piece extending toward the lower side between the U-shaped slots is bent toward the back side in the depth direction and hooked on the plug shell from the lower side to assemble onto the end of the shielded cable.