Variable-Diameter Electrical Ferrule for Multi-Size Cable Crimping
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Solution Overview
Problem
Conventional ferrules for high-frequency electrical connectors are limited to specific cable types and sizes, leading to manufacturing difficulties and an inability to achieve an ideal fit with cables of varying diameters and tolerances, necessitating multiple ferrule types and compromising connector performance.
Innovation Solution
A variable-diameter ferrule design with self-locking flanks and latching mechanisms that can adapt to different cable diameters during installation, allowing for a range of cable sizes to fit within existing shielding contact sleeves, ensuring secure crimping and optimal electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ferrules are used for specific cable types and sizes, then manufacturing precision is improved, but device complexity increases due to needing multiple ferrule types
Solution Approach 1:
The ferrule is designed with a variable diameter capability that allows a single ferrule type to accommodate multiple cable diameters and types. The at least one latch or lock defined on the flanks enables the ferrule to adjust its effective diameter, making one ferrule design universal for various cable specifications rather than requiring separate ferrules for each cable type.
Solution Approach 2:
The ferrule incorporates dynamic adjustment capability through the latch or lock mechanism on its flanks. This allows the ferrule diameter to vary during installation to match different cable diameters, transforming a static component into a dynamic one that adapts to different conditions while maintaining precise fit.
2Manufacturing precision
If ferrule diameter is fixed, then manufacturing precision is improved, but adaptability decreases for varying cable diameters
Solution Approach 1:
The ferrule transitions from a fixed diameter design to a dynamic variable diameter design. The latch or lock mechanism allows the ferrule to adjust its diameter within a range, enabling it to adapt to different cable diameters while maintaining precise dimensional control through the defined locking positions.
Solution Approach 2:
The ferrule's diameter parameter is made variable rather than fixed. By incorporating latches or locks that can engage at different positions, the effective diameter of the ferrule can be changed to match different cable diameters, allowing one ferrule design to cover a range of dimensional parameters.
3Adaptability or versatility
If multiple ferrule types are used for different cables, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of maintaining multiple specialized ferrule types in inventory, the invention creates a universal ferrule design with variable diameter capability. This single ferrule type can accommodate different cable types and sizes through its adjustable latch or lock mechanism, simplifying inventory management while maintaining broad cable compatibility.
Solution Approach 2:
The invention merges the functionality of multiple ferrule types into a single ferrule design. By combining the diameter adjustment capability with the basic ferrule structure, it consolidates what would require multiple separate components into one multi-functional component, reducing overall system complexity.
4Ease of operation
If ferrule diameter varies during installation, then ease of operation is improved, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The ferrule is designed to be dynamic during installation, allowing diameter variation to accommodate different cable sizes. The latch or lock mechanism provides controlled variability, enabling easy installation on different cables while maintaining precision through defined locking positions that ensure proper fit once installed.
Solution Approach 2:
The latch or lock mechanism is pre-configured with defined positions that correspond to different cable diameters. This preliminary arrangement of locking positions allows the installer to select the appropriate position based on cable size, providing both ease of operation and manufacturing precision without requiring complex real-time adjustments.
Data Source
AI summary
An electrical ferrule for an electrical cable comprises a body defining a circumferential center portion connecting a first flank and a second flank, the first and second flanks arranged opposite one another in a radial direction of the ferrule. At least one latch or lock is defined on at least one of the flanks for selectively fixing the flanks together and closing the ferrule in a manner in which a diameter of the ferrule may be varied during its installation onto an electrical cable.