Shielded Connector Assembly With Crimped Dielectric Locking

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Solution Overview

Problem

The existing connector structures for coaxial cables face issues with dielectric deformation due to heat during the welding process, leading to potential electrical connectivity problems.

Innovation Solution

A connector structure is designed with a shielded cable configuration where the dielectric is crimped by a rear outer conductor from the outside, eliminating the need for welding and thus preventing heat-induced deformation. This involves a manufacturing method that includes exposing the core, arranging an inner conductor, connecting it to the core, crimping the dielectric, and locking it with a front outer conductor, ensuring reliable electrical connections without heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the contact member and connecting member are welded together, then electrical connection is achieved, but the dielectric may deform due to heat during welding

Engineering Contradiction:

Improveelectrical connectionVSAvoiddielectric shape

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces the thermal welding process with a mechanical crimping system. The outer conductor includes a crimping portion that mechanically deforms to create electrical contact with the inner conductor, eliminating the need for heat-based welding and thus preventing dielectric deformation while achieving reliable electrical connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the connection method from thermal (welding) to mechanical (crimping). The crimping portion is designed to undergo controlled plastic deformation under compression force, transforming the connection mechanism from heat-dependent to force-dependent, which resolves the contradiction between achieving electrical connection and preventing dielectric deformation.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If welding is used to connect contact member and connecting member, then electrical connectivity is established, but heat-induced deformation of dielectric occurs

Engineering Contradiction:

Improveelectrical connectivityVSAvoidheat damage to dielectric

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes the welding process with a mechanical crimping mechanism. The outer conductor's crimping portion is designed to compress and deform the inner conductor, creating reliable electrical connectivity through cold-flow metal deformation rather than thermal bonding, thereby eliminating heat damage to the dielectric.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the potential harm of heat application into a benefit by completely eliminating the heating step. The crimping process uses controlled mechanical force that deforms the metal components to create electrical contact without generating harmful thermal effects on surrounding materials, particularly the dielectric.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 approach effectively suppresses dielectric deformation caused by heat, ensuring reliable and heat-free connections between the rear and front outer conductors, thereby enhancing the electrical reliability and positional accuracy of the connector structure.

Implementation Method 1

a rear outer conductor including a shield connecting portion to be electrically connected to the shield portion and a dielectric crimping portion to be crimped to at least a part of the dielectric from outside

Methodology Applied

Scientific EffectCrimping: Plasticity

Implementation Method 2

a front outer conductor including a tube portion for surrounding an outer periphery of the dielectric and a rear outer conductor locking portion for locking at least a part of the dielectric crimping portion from outside

Methodology Applied

Scientific EffectMechanical locking: Mechanical Fastener

Data Source

PatentUS11837834B2Connector structure, and connector structure manufacturing method

Publication Date: 2023.12.05 AUTONETWORKS TECH LTD

AI summary

A female connector structure is provided with a shielded cable configured such that an outer periphery of a coated wire including a core and an insulation coating is surrounded by a braided wire, a female terminal including a wire barrel to be connected to the core and a connecting tube portion and to be connected to a mating terminal, an insulating dielectric for surrounding an outer periphery of the connecting tube portion of the female terminal, a rear outer conductor including a shield connecting portion to be electrically connected to the braided wire and a dielectric crimping portion to be crimped to at least a part of the dielectric from outside, and a front outer conductor including a front tube portion for surrounding an outer periphery of the dielectric and a rear outer conductor locking portion for locking at least a part of the dielectric crimping portion from outside.