Tapered Support Sleeve for Electric Cable Axial Positioning
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Solution Overview
Problem
Existing electrical cable assemblies face challenges in achieving a mechanically and electrically optimized connection between the support sleeve and the outer conductor element, particularly in high-frequency applications, with issues in axial positioning and impedance matching, which are critical for robust and reliable connections in automotive and autonomous vehicle systems.
Innovation Solution
A pre-assembled electrical cable design featuring a support sleeve with a tapered cable-side end section that allows for precise axial positioning and crimping, ensuring a stable connection with the outer conductor element, and a connector arrangement that includes a support sleeve with tapered sections and a folded-back outer conductor shield for improved mechanical and electrical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a support sleeve is attached to an outer conductor shield of an electrical cable, then mechanical connection is achieved, but precise axial positioning and impedance matching are difficult to achieve
Solution Approach 1:
A positioning element is introduced as an intermediary component between the support sleeve and the outer conductor element. This positioning element features a tapered section that facilitates precise axial positioning during the crimping process, enabling the support sleeve to be accurately positioned relative to the outer conductor element while maintaining connection reliability.
Solution Approach 2:
The positioning element incorporates a tapered section with a gradually changing diameter, transforming the geometric parameters along its length. This tapering geometry enables controlled axial positioning by providing a progressive fit during crimping, thereby achieving precise positioning without compromising connection reliability.
2Strength
If the support sleeve is crimped to the outer conductor element, then mechanical stability is improved, but impedance discontinuities increase
Solution Approach 1:
The positioning element serves as a mediator between the support sleeve and the outer conductor element during crimping. Its tapered geometry distributes the crimping force progressively, maintaining impedance continuity while achieving the necessary mechanical stability through controlled deformation.
Solution Approach 2:
The tapered section of the positioning element employs a curved, gradually changing cross-section rather than an abrupt geometric discontinuity. This curved geometry minimizes impedance discontinuities by providing a smooth transition during crimping, while still achieving adequate mechanical stability.
3Volume of moving object
If the connector is designed to be compact, then space and weight are reduced, but axial positioning accuracy deteriorates
Solution Approach 1:
The positioning element is nested within the compact connector structure, utilizing the existing space efficiently. The tapered positioning element fits within the connector housing and outer conductor element assembly, providing precise axial positioning functionality without significantly increasing the overall connector volume.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a prefabricated electric cable (3) comprising an outer conductor shield (2) and a support sleeve (1) which is fastened to the outer conductor shield (2) and which has an end (4) closer to the plug and an end (5) closer to the cable. According to the invention, in an end portion (6) closer to the cable, the support sleeve (1) tapers towards the end (5) closer to the cable.