Shielded Cable Connector Single Crimp Termination
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Solution Overview
Problem
Conventional shielded cable termination systems are complex, costly, and lack reliability due to multiple parts and crimping operations, which can lead to misassembly and environmental vulnerabilities.
Innovation Solution
A single connector system with a strategically oriented termination collar that provides electrical termination, strain relief, and environmental protection through a single crimping action, using a cylindrical housing and termination ferrule to engage the shield layer and offer electro-mechanical interface functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional detachable connectors and bolted connections are used, then environmental protection and strain relief can be provided, but the number of parts and crimping operations increases, reducing reliability and increasing cost
Solution Approach 1:
The patent combines multiple functions (environmental protection, strain relief, and cable shield termination) into a single integrated connector assembly. The collar structure integrates the gland enclosure seal, strain relief elements, and shield termination components into one unified part that requires only a single crimping operation, eliminating the need for multiple discrete parts and sequential assembly steps.
Solution Approach 2:
The connector assembly performs multiple functions simultaneously: it provides environmental sealing through the gland enclosure, strain relief through the cable grip mechanism, and electrical termination for the shield layer. This multi-functional design eliminates the need for separate components for each function, reducing overall system complexity while maintaining all required protective and terminative capabilities.
2Ease of operation
If multiple discrete elements are used for electrical and mechanical interfaces, then specific functions can be provided, but assembly complexity and potential for misassembly increases
Solution Approach 1:
The electrical interface and mechanical interface are merged into a single connector assembly. The collar simultaneously provides mechanical strain relief through its cable grip structure and electrical termination through the integrated shield termination mechanism, eliminating the need for separate mechanical and electrical components and their associated assembly steps.
Solution Approach 2:
The connector is pre-configured with the collar, gland enclosure seal, and termination features integrated before installation. This preliminary integration ensures that all functional elements are properly positioned and configured in advance, eliminating the need for complex field assembly and reducing the risk of misassembly during installation.
3Ease of manufacture
If many parts are joined with multiple crimping operations, then electrical and mechanical functions can be achieved, but cost and manufacturing complexity increase
Solution Approach 1:
Multiple crimping operations are merged into a single crimping action. The collar structure is designed so that one crimping operation simultaneously secures the cable, engages the gland enclosure seal, and terminates the shield layer, eliminating the need for multiple sequential crimping steps and reducing manufacturing complexity and cost.
Solution Approach 2:
The single crimping operation performs multiple functions: it provides mechanical retention of the cable, establishes environmental sealing through the gland enclosure, and creates electrical termination for the shield. This multi-functional crimping approach reduces manufacturing steps while ensuring all required functions are achieved in one reliable operation.
Data Source
AI summary
A system and method for a shielded coaxial cable including a collar including a cylindrical housing having a cylindrical inner bore, the inner bore having top and bottom openings the top opening having a diameter about equal to an outer diameter of an outer insulating layer of the cable and the bottom opening having a diameter about equal to an outer diameter of a shield layer of the cable with a terminating portion of the shield layer exposed and returned over an exterior portion of said collar near the bottom opening with the terminating portion overlapping said exterior portion; and a termination ferrule joined to the terminating portion that overlaps the exterior portion to simultaneously provide an electrical communication between the shield layer and the collar and provide a strain relief for the shielded cable disposed within the inner bore.