Welded Coaxial Wire Contact for RF Impedance Matching
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Solution Overview
Problem
Existing wire connector assemblies for coaxial cables, particularly in automotive applications, face challenges with mechanical adherence methods like crimping and soldering, which require orientation and can introduce impedance mismatches affecting RF performance.
Innovation Solution
A wire assembly with a contact welded to the tip of the inner conductor, eliminating the need for crimping or soldering, where the contact is non-oriented and can be securely attached with percussion welding, reducing the length of dielectric insulator stripping and minimizing impedance mismatches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping or soldering is used to attach the contact to the inner conductor, then mechanical connection is achieved, but orientation requirements and impedance mismatches occur
Solution Approach 1:
The patent replaces the mechanical crimping system with a welding system. Instead of using mechanical force to deform the contact and inner conductor together, the invention uses welding to create a direct metallurgical bond between the contact tip and the exposed inner conductor tip, eliminating the need for mechanical deformation and associated orientation requirements.
Solution Approach 2:
The patent changes the attachment method parameter from mechanical (crimping force, deformation) to thermal/electrical (welding current, temperature). This parameter change allows for a more precise control of the joint formation process, reducing impedance mismatches caused by mechanical deformation and improving RF performance.
2Reliability
If crimping is used to attach the contact to the inner conductor, then electrical connection is achieved, but contact orientation is required during assembly
Solution Approach 1:
The patent replaces the mechanical crimping system with a welding system. Instead of using mechanical force to deform the contact and inner conductor together, the invention uses welding to create a direct metallurgical bond between the contact tip and the exposed inner conductor tip, eliminating the need for mechanical deformation and associated orientation requirements.
Solution Approach 2:
The patent inverts the traditional approach by exposing the tip of the inner conductor and welding the contact to it, rather than inserting the inner conductor into the contact and crimping. This inversion allows the contact to be attached in any orientation, simplifying the assembly process.
3Ease of manufacture
If longer length of dielectric insulator is stripped for crimping, then contact attachment is achieved, but impedance mismatches increase
Solution Approach 1:
The patent replaces the mechanical crimping system with a welding system. Instead of using mechanical force to deform the contact and inner conductor together, the invention uses welding to create a direct metallurgical bond between the contact tip and the exposed inner conductor tip, eliminating the need for mechanical deformation and associated orientation requirements.
Solution Approach 2:
The patent performs preliminary exposure of the inner conductor tip before the welding operation. By exposing only the necessary length of the inner conductor tip and then immediately welding the contact to it, the invention prevents the need for longer insulator stripping that would occur with crimping, thereby maintaining impedance matching.
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 enhances RF performance by reducing impedance mismatches and allows for a more reliable, low-cost, and automated manufacturing process with improved mechanical strength and ease of assembly.
Implementation Method 1
The contact is welded to the tip of the inner conductor at the first end
Data Source
Figure 1A~1B
Figure 2A
Figure 2B~2C
AI summary
A wire assembly includes a cable and a contact. The wire includes at least an inner conductor and an insulating jacket surrounding the inner conductor, wherein a tip of the inner conductor is exposed at a first end. The contact is welded to the tip of the inner conductor at the first end.