Splice Connector Insulator Layout for Pair Impedance Control
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Solution Overview
Problem
Existing splicing methods for electrical cables with conductor pairs, such as unshielded twisted pair cables, fail to adequately control capacitive coupling and impedance, making them unsuitable for harsh environments like automobiles, ground vehicles, marine, or aerospace applications.
Innovation Solution
An electrical splice connector comprising two crimped splice terminals and a dividing insulator formed of dielectric material with separated cavities, controlled capacitive coupling through openings or reduced thickness in the wall, and covered by heat shrink tubing to maintain mechanical strength and electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional splicing methods (twisting, IDC, press fit) are used to connect electrical cables, then the splicing process is simple and easy to manufacture, but the capacitive coupling between contact pairs is not well controlled which affects impedance and frequency response characteristics
Solution Approach 1:
The connector is divided into separate contact pair assemblies, each with its own insulator body and conductive members. This segmentation allows independent control of capacitive coupling for each contact pair while maintaining overall connector functionality.
Solution Approach 2:
An insulator body is introduced as an intermediary component between conductive members to control and manage capacitive coupling. The insulator body with specific geometric features acts as a mediator that establishes predetermined capacitive coupling values while maintaining electrical isolation.
2Reliability
If traditional splicing methods are used, then the splicing process is quick and efficient, but the connectors cannot meet mechanical, electrical, and environmental requirements in harsh environments such as automobiles, marine, or aerospace vehicles
Solution Approach 1:
Multiple functions are merged into a single connector design: mechanical strength through crimping, electrical connection through conductive members, insulation through insulator bodies, and environmental protection through sealed construction. This integration achieves harsh environment reliability while maintaining manufacturing efficiency.
Solution Approach 2:
The connector uses composite construction combining conductive members (metal) with insulator bodies (dielectric material), creating a structure that simultaneously provides electrical conductivity, insulation, mechanical strength, and environmental durability suitable for harsh conditions.
3Manufacturing precision
If conductors are stripped back to expose them for connection, then physical and electrical connection can be established, but the insulation is compromised and capacitive coupling cannot be controlled
Solution Approach 1:
The insulator body is prepared in advance with predetermined geometric features and cavities that will control capacitive coupling. This preliminary preparation allows precise impedance control without requiring complex post-assembly adjustments or extensive conductor stripping.
Solution Approach 2:
The insulator body provides localized insulation and capacitive coupling control at specific contact pair locations. Different regions of the insulator body have different geometric features tailored to control the capacitive coupling of individual contact pairs, enabling precise impedance management.
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
The connector provides reduced signal attenuation and impedance matching, suitable for harsh environments by controlling capacitive coupling and electromagnetic interference, ensuring mechanical and electrical integrity.
Implementation Method 1
a first splice terminal crimped to a first wire conductor of a first wire cable and crimped to a first wire conductor of a second wire cable
Implementation Method 2
the capacitive coupling between the contact pairs is not well controlled which may affect the impedance of the splice connection
Implementation Method 3
a dividing insulator formed of a dielectric material having a first cavity in which the first splice terminal is disposed
Implementation Method 4
The second cavity is separated from the first cavity by a wall formed of the dielectric material
Data Source
AI summary
An electrical splice connector may include a first splice terminal crimped to a first wire conductor of a first wire cable and crimped to a first wire conductor of a second wire cable. An electrical splice connector may include a second splice terminal crimped to a second wire conductor of the first wire cable and crimped to a second wire conductor of the second wire cable. An electrical splice connector include a dividing insulator formed of a dielectric material having a first cavity in which the first splice terminal is disposed and having a second cavity in which the second splice terminal is disposed. The second cavity is separated from the first cavity by a wall formed of the dielectric material.