Tapered Support Sleeve for Impedance-Matched Cable Connections
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Solution Overview
Problem
Existing prefabricated electric cables with support sleeves fail to achieve a satisfactory mechanical and electrical connection with electrical connectors, particularly in high-frequency applications, due to inadequate axial positioning and impedance matching, which is critical for robust and vibration-proof connections in automotive and autonomous vehicle systems.
Innovation Solution
A prefabricated electric cable design featuring a support sleeve with a tapering cable-side end portion that tapers in the direction of the cable-side end, allowing for improved axial positioning and mechanical/electrical connection, achieved through a crimping process that generates or reinforces the taper, ensuring a stable and impedance-matched connection with the outer conductor element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support sleeve is attached to an outer conductor shield of an electric cable, then mechanical connection is achieved, but axial positioning precision and impedance matching remain insufficient
Solution Approach 1:
The support sleeve is pre-formed with a tapering cable-side end portion before attachment to the outer conductor shield. This preliminary geometric configuration enables precise axial positioning during the crimping process, resolving the contradiction between mechanical connection reliability and axial positioning precision by preparing the positioning feature in advance.
Solution Approach 2:
The support sleeve features a varying diameter along its cable-side end portion, transitioning from a larger diameter at the connector-side end to a smaller diameter at the cable-side end. This parameter change in geometry creates a tapered structure that improves both mechanical connection reliability and axial positioning precision during assembly.
2Weight of stationary object
If connectors are made compact to save installation space and weight, then device size is reduced, but mechanical stability and vibration-proof connection become difficult to achieve
Solution Approach 1:
The support sleeve is inserted into the outer conductor element of the connector, creating a nested structure. This nesting approach allows the support sleeve to provide enhanced mechanical stability and vibration resistance within the compact connector housing, resolving the contradiction between compact size and mechanical strength.
3Strength
If the support sleeve is deformed during crimping to attach to the outer conductor shield, then mechanical attachment is achieved, but geometric discontinuities may affect impedance matching
Solution Approach 1:
The support sleeve has different geometric characteristics at different locations: a tapering cable-side end portion for precise positioning and attachment to the outer conductor shield, and a substantially cylindrical connector-side end portion for clean attachment to the outer conductor element. This local differentiation ensures that deformation occurs in controlled regions, maintaining impedance matching while achieving strong mechanical attachment.
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 tapering support sleeve design enhances the mechanical and electrical connection reliability, compensates for assembly tolerances, and provides a clearance-free fastening, ensuring a stable and efficient data transfer in high-frequency applications, particularly suitable for automotive and autonomous systems.
Implementation Method 1
a cable-side end portion (6), in particular designed in such a way that it can be deformed by a deforming process (in particular a crimping process) in such a way that, after the deforming process, the cable-side end portion (6) tapers in the direction of the cable-side end (5)
Data Source
AI summary
Embodiments of a prefabricated electric cable may have an outer conductor shield and a support sleeve which is fastened to the outer conductor shield. The support sleeve has a cable-side end and a portion of the support sleeve tapers in an axial direction oriented toward the cable-side end.