Wafer Connector Grounding Clamp for Twin-Axial Wire Termination
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Solution Overview
Problem
Existing wafer connectors for drainless cable systems require complex and costly manufacturing processes due to the need for individual termination of twin-axial wires, leading to increased labor and size, and lack an efficient means to interconnect multiple grounding foils.
Innovation Solution
A grounding clamp with an elongated conductive body formed from two halves, featuring peaks and valleys that securely hold twin-axial wires together and provide multiple connection points for easy termination to wafer connector ground terminal tails, allowing for automated assembly and additional shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual termination of twin-axial wires is used in drainless cable systems, then reliable grounding contact is achieved, but manufacturing complexity and labor increase
Solution Approach 1:
The grounding clamp merges multiple individual grounding contacts into a single integrated component. The clamp simultaneously contacts the conductive foils of multiple wire pairs through its conductive body, replacing the need for individual termination of each twin-axial wire. This combining approach maintains reliable grounding while significantly reducing manufacturing complexity and labor requirements.
Solution Approach 2:
The grounding clamp serves multiple functions simultaneously: it provides grounding contact with conductive foils, holds wire pairs in proper alignment, and facilitates automated assembly. This multi-functional design eliminates the need for separate components for each function, reducing overall device complexity while maintaining reliable grounding contact.
2Reliability
If specially formed nests are used in ground terminals for drainless systems, then grounding contact with conductive foil is achieved, but connector height and manufacturing cost increase
Solution Approach 1:
Instead of forming complex nests within the ground terminal to contact the conductive foil, the invention inverts the approach by placing a conductive clamp over the wire pairs that makes contact with the conductive foil. This reverses the traditional nesting concept, achieving the same grounding contact function while significantly reducing the height of the ground terminal in the connector.
3Reliability
If manual termination of wires to ground terminals is performed, then proper grounding connection is achieved, but labor requirements and assembly time increase
Solution Approach 1:
The grounding clamp is pre-assembled with the wire pairs before insertion into the connector. The clamp pre-establishes the grounding contact with the conductive foils and holds the wire pairs in proper alignment. This preliminary action eliminates the need for manual termination operations during final assembly, significantly increasing productivity while maintaining reliable grounding connections.
4Reliability
If multiple individual ground terminals are used for each wire pair, then individual grounding is achieved, but connector size and cost increase
Solution Approach 1:
The invention merges multiple individual ground terminals into a single grounding clamp that serves all wire pairs. The conductive body of the clamp provides simultaneous grounding contact with the conductive foils of multiple wire pairs, eliminating the need for separate ground terminals for each pair. This significantly reduces the connector footprint and manufacturing cost while maintaining individual grounding for each wire pair.
Data Source
AI summary
A wafer connector is disclosed in which a plurality of twin-axial wires are terminated to the tails of ground and signal terminals of the connector. Each twin-axial wire includes a pair of signal wires enclosed in a conductive sheath. A conductive grounding clamp is provided that contacts the sheaths of the twin-axial wires and holds them together as a unit to facilitate the attachment of the wires to the connector terminal tails. The clamp has two opposing halves that cooperatively define openings which receive the twin-axial wires and flat, interconnecting portions extending between the openings that provide contact points where the grounding clamp may be attached to the connector terminal tails.