Stepped Outer Contact Cavity Insert for FAKRA Connectors
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Solution Overview
Problem
Current connector assemblies face challenges in accommodating larger diameter cables due to space restrictions within the outer housings, making it difficult to load a cavity insert over the outer contact while maintaining secure positioning and compatibility with standardized FAKRA connectors.
Innovation Solution
The design incorporates a stepped outer contact with a mating segment, a middle segment, and a terminating segment of varying diameters, allowing the cavity insert to fit within the fixed cavity of the outer housing by using a two-piece construction for the cavity insert, which is assembled around the middle segment, enabling accommodation of larger cables while maintaining secure retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cavity insert size is increased to accommodate larger diameter cables, then the cable accommodation capability is improved, but the space restrictions within the outer housing are exceeded
Solution Approach 1:
The cavity insert is divided into two separate pieces: a first cavity insert piece and a second cavity insert piece. These pieces are assembled together around the outer contact to form the complete cavity insert. This segmentation allows the insert to be constructed in a modular fashion that accommodates larger cable diameters without requiring a single large-volume piece that would exceed outer housing restrictions.
Solution Approach 2:
The two cavity insert pieces are nested together, with the first piece positioned within or adjacent to the second piece, forming a combined structure. This nested arrangement allows the cavity insert to achieve the necessary internal volume for larger cables while maintaining an external profile that fits within the outer housing cavity space constraints.
2Adaptability or versatility
If a two-piece construction is used for the cavity insert to accommodate larger cables, then the cable accommodation capability is improved, but the assembly complexity increases
Solution Approach 1:
The cavity insert is segmented into two pieces that can be separately manufactured and then assembled. This segmentation reduces the manufacturing complexity of each individual piece while allowing the combined structure to accommodate larger cables. The pieces are designed to fit together in a straightforward manner around the outer contact.
Solution Approach 2:
The two cavity insert pieces are merged together during assembly to form the complete cavity insert structure. This combining process integrates the two simpler components into a functional unit that provides the necessary cable accommodation capability, effectively reducing overall device complexity through modular construction.
3Adaptability or versatility
If the outer contact diameter is increased to accommodate larger cables, then the cable accommodation capability is improved, but the ability to load the cavity insert over the outer contact is compromised
Solution Approach 1:
The cavity insert is segmented into two pieces that can be assembled around the outer contact in a step-by-step process. This segmentation allows the insert to be constructed in a modular fashion that accommodates larger cable diameters without requiring a single large-volume piece that would exceed outer housing restrictions.
Solution Approach 2:
The two cavity insert pieces are preliminarily assembled around the outer contact before final installation into the outer housing. This preliminary assembly action allows the insert to be configured to match the outer contact dimensions, ensuring proper fit and facilitating the subsequent loading process into the housing cavity.
Data Source
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AI summary
A connector assembly (104) includes a center contact (180) configured to be terminated to a center conductor (170) of a cable (108). A dielectric (182) holds the center contact. An outer contact (184) surrounds the dielectric and the center contact. The outer contact has a mating segment extending from a mating end, a terminating segment extending from a cable end, and a middle segment between the mating and terminating segments. The terminating segment is configured to be terminated to a braid (174) of the cable. The middle segment has a diameter that is less than the respective diameters of the mating and terminating segments. A cavity insert (188) surrounds the middle segment of the outer contact. The cavity insert includes a receiving shell and a closing shell that are joined together at an interface.