Threaded Cable Connector Assembly for Solderless Filter Unit Coupling

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Solution Overview

Problem

Conventional filter units in cellular base stations require soldered connections for cables, which are difficult to remove and can cause damage when disassembled, and lack consistent metal-to-metal connections, leading to issues like Passive Intermodulation (PIM) distortion and increased insertion loss.

Innovation Solution

The development of connector assemblies that provide a solderless, threaded connection to filter units, using a first member with an open channel and a second member with external threads to engage a receiving channel, allowing for easy detachment and consistent electrical contact without soldering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldered connections are used for cables to filter units, then electrical connection reliability is improved, but ease of repair deteriorates and damage risk increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidease of cable replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The invention divides the connection system into separable components: a connector assembly with a coupling member that interfaces with the filter unit housing, and a cable assembly that can be independently replaced. The coupling member includes a body portion that engages with a receiving channel in the housing, creating a mechanical connection that replaces the traditional soldered joint while allowing for easy disassembly and reassembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces the thermal/mechanical soldering process with a purely mechanical threaded engagement system. The coupling member features external threads that engage with internal threads in the receiving channel, providing a reliable electrical and mechanical connection without requiring heat, solder, or complex assembly tools, thereby enabling easy field replacement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If soldered connections are used for cables to filter units, then electrical connection stability is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidease of cable assembly manufacturing

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The connector assembly is pre-assembled with the coupling member attached to the cable assembly before final installation at the filter unit. This preliminary assembly allows for quality control, testing, and verification to be performed on the connector-cable assembly as a complete unit, ensuring proper thread engagement, electrical contact, and mechanical strength before deployment, thereby simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Ease of repair

If threaded connector assemblies are used instead of soldered connections, then ease of repair is improved, but device complexity increases

Engineering Contradiction:

Improveease of cable replacementVSAvoidconnector assembly complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The coupling member is designed to perform multiple functions within a single component: it provides mechanical support for the cable, establishes electrical contact through its conductive body, creates a sealed interface with the housing, and enables easy installation and removal through threaded engagement. This multi-functionality reduces the need for separate components and simplifies the overall assembly despite the added capability of easy replacement.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution enables easy replacement of cables, reduces damage from soldering, and maintains consistent metal-to-metal connections, thereby minimizing PIM distortion and insertion loss, while allowing for standardized testing and assembly without unit-specific cables.

Implementation Method 1

cables that comprise connector assemblies that releasably couple to a receiving channel of a housing using a threaded member thereby providing a solderless connection to the housing

Methodology Applied

Scientific EffectThreading: Screw

Data Source

PatentUS12184015B2Cables with connector assemblies, filter units configured to releasably couple to the connector assemblies and related methods

Publication Date: 2024.12.31 COMMSCOPE ITAL SRL

AI summary

The present invention provides target devices such as filter units with at least one receiving channel with a stop surface that is electrically conductive and at least one cable with a connector assembly on a first end portion. The connector assembly includes a first member with an open channel. The first member is coupled to the end portion of the outer conductor with the free end of the inner conductor and the end portion of the dielectric extending through the open channel to reside forward of the first member. The first member resides in a respective one of the at least one receiving channel against the stop surface. The connector assembly also includes second member with an open channel. The second member is slidably coupled to the first end portion of the at least one cable and presses the first member against the stop surface.