High voltage vertical disc ferrule and wire structure and method of assembly thereof

Abstract

A high-voltage vertical disk ferrule and its assembly method are provided, in which the ferrule is stamped and has a vertical disk-like structure, not necessarily circular, and not necessarily rounded in any way. The high-voltage vertical disk ferrule has an opening that fits around and moves around at least one of a wire core and a wire braid shield, and an end portion of the wire braid shield is secured to the ferrule or between two ferrules so that a portion of the wire braid shield is flared and substantially perpendicular to the direction in which the wire core extends. The high-voltage vertical disk slides around the core insulator and toward the outer insulator when the wire is pushed. The wire braid shield generates a natural spring force against the ferrule, causing the ferrule to accordion, crimp, or fold against itself, thus pushing the vertical disk ferrule forward.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This patent application claims priority to U.S. Provisional Patent Application No. 63 / 051,517, filed July 14, 2020, the entire contents of which are incorporated herein by reference.

[0002] [Technical field to which the invention belongs] The present invention relates generally to the field of electrical connectors, ferrules, and wire / cable shield interfaces useful in automotive or vehicle applications.

[0003] [Description of Related Art] In the automotive industry, as shown in FIG. 1A , a related art ferrule 1 is understood to be a horizontal ferrule 1, which is horizontal or parallel to the direction of the wire core 3 of the wire 5. Therefore, the contact surface (i.e., between the connector and the wire shield) is parallel to the direction of the wire core 3. In the related art ferrule 1, as shown in FIG. 1A , the horizontal ferrule 1 extends parallel to the direction of the corresponding wire core 3 and is further crimped onto the wire 5. As further shown in FIG. 1A , the horizontal surface 11 of the related art ferrule 1 is much larger (i.e., typically several orders of magnitude larger) than the vertical surface 7, which essentially constitutes the material thickness of the ferrule 1. Therefore, the horizontal surface 11 constitutes the ground surface of the related art ferrule 1, which is horizontal (i.e., parallel to its wire core 3) and allows a ground or shielding function within the connector housing (not shown) to interact with the horizontal side of the ferrule 1. In use, the ferrule 1 is crimped onto the wire braid shield 10 and is therefore also secured to the wire 5 in the process.

[0004] Typically, it is industry practice to use two ferrules (an inner ferrule and an outer ferrule) to sandwich the wire braided shield 10 between them. This structural arrangement in the related art ensures contact between the ferrule 1 and the wire shield 10. As shown in FIG. 1A, the ferrule 1 generally consists of two ferrules: an inner ferrule 1A and an outer ferrule 1B. The inner ferrule 1A is placed around the wire core insulation 12, and the wire braided shield 10 is folded or placed along its length (across the horizontal plane of the inner ferrule 1A). The outer ferrule 1B is then placed around the wire braided shield 10, aligned with the inner ferrule 1A, and crimped. In this manner, the crimping process of the ferrule 1 secures the inner and outer ferrules of the ferrule 1 to the wire braided shield 10. During use and after crimping, the ferrule 1 also prevents the outer insulation 13 from moving toward the wire core 3 over time. The use of two ferrules 1 over the wire core insulation 12 also ensures that the ferrules 1 and wire braid shield 7 do not cut through the wire core insulation 12 and ground the power circuit.

[0005] Furthermore, for intended use in a connector housing (not shown), ferrule 1 of FIG. 1A must be long enough (typically 6-15 mm long) to accommodate tolerance stack-up within the connector housing (not shown), so that the two ferrules 1a, 1b are long enough to ensure they are aligned on top of each other when crimped. The tolerance stack-up ensures that there is always contact between ferrule 1 and the stamped metal shield (not shown) within the connector housing (not shown). However, sufficient length of ferrule 1 also requires a corresponding length in the connector housing.

[0006] When the ferrule 1 is crimped, it is fixed in position relative to the corresponding wire 5 and the corresponding outer insulation 13 of the wire 5. Once crimped, the ferrule 1 requires sufficient force to move. Therefore, this related art ferrule 1 is not designed to move or slide after crimping is complete. In other words, the conventional ferrule 1 is configured not to move or slide along the wire core insulation 15 of the wire core 3. The crimped surface of the ferrule 1 has ridges, valleys, and burrs and does not remain in its uncrimped state or shape.

[0007] After related art ferrules are crimped and assembled, it is typically necessary to provide an additional or secondary cut to the wire braid shield 10. The total exposed length of the wire braid shield 10 should not exceed twice the length of the ferrule 10. This problem arises when frayed wires from the braid shield 10 could contact the power circuit of the wire 5 (wire core 3 or connected terminal (not shown)).

[0008] 1B illustrates the use of a flared ferrule 2. The flared ferrule 2 comprises a large-diameter flared portion 14 and a small-diameter narrow portion 15, which surrounds and contacts the wire shield 10. The narrow portion is the portion 15 of the related art ferrule 1 that is crimped onto the wire 5 during use. Crimping the narrow portion 15 onto the wire 5 restricts the flared ferrule 2 from moving or sliding toward or beyond the outer insulation 13 during use. Contact between the flared ferrule 2 and the shield 10 provided in the connector housing is provided at the flared portion 14, the shape of which remains substantially unchanged after the crimping process performed on the narrow portion 15.

[0009] Furthermore, the related art ferrule 1 can be used with a stamped metal shield (not shown) having a tab. The tab (not shown) contacts the ferrule 1 at its horizontal surface 1b, creating a ground contact between the ferrule 1 and the shield. The horizontal surface 1b of the ferrule 1 is parallel to the insertion direction of the wire 5. The ferrule 1 requires sufficient space in the connector housing (not shown) to fully accommodate the ferrule 1 and allow contact between the ferrule 1 and the shield. The required space must be large enough to allow the terminal (not shown) to pass through and is often larger than the size of the vertical surface 1b of the ferrule 1. Therefore, the ferrule 1 provides little or no EMI shielding or coverage. Summary of the Invention [Problem to be solved by the invention]

[0010] Therefore, it is desirable that the structure or structural arrangement of the ferrule be capable of providing complete or substantial EMI shielding, allowing for complete coverage within the opening of the respective connector housing in which it is used, that the ferrule not require a secondary cut when secured to the wire braid shield, thereby minimizing or reducing the possibility of frayed wires of the wire braid shield (ground circuit) contacting the wire core (power circuit), and that the ferrule provide for roll-up or tolerance tolerances to improve the assembly method. [Means for solving the problem]

[0011] The present invention relates to a high-voltage vertical disk ferrule (plate-shaped base) and its assembly method. More specifically, the high-voltage vertical disk ferrule of the present invention is a vertical disk-shaped structure, but this disk-shaped structure is formed primarily of flat surfaces, and the periphery, edges, or vertical shape or its defining features are not necessarily circular or necessarily rounded in any way. The high-voltage vertical disk ferrule of the present invention is a conductive device having a through hole or aperture at its center. The through hole or aperture is placed around a wire core and a wire braided shield, and the end of the wire braided shield is secured to or secured between the high-voltage vertical disk ferrule so that a portion of the wire braided shield is flared and substantially perpendicular to the direction of the wire core. The central aperture or aperture of the high-voltage vertical disk ferrule of the present invention accommodates at least one of a wire core, a wire core insulation, and a wire braided shield, and the wire braided shield surrounds the wire core insulation.

[0012] Once secured to the wire braid, the vertical-disk ferrule of the present invention slides over the core insulator toward the point or location where the outer insulation is to be cut (the vertical surface of the outer insulation). This assembly method pushes back the wire braid, allowing the wire braid to generate a natural spring force against the vertical-disk ferrule, compressing, bellowing, crimping, or folding back on itself, thus forcing the vertical-disk ferrule forward (toward the cut end of the attached wire or terminal) in the direction the ferrule moved along the wire core when the wire was being pushed. This force allows the vertical-disk ferrule or wire braid, if there is one between them, to remain in contact with the connector's gland structure during use, or to press the wire braid against the housing or ferrule when used as a single ferrule.

[0013] The ability of the disk-like structure or structural arrangement of the present invention to assume any shape that it can be stamped also enables it to provide complete or near complete electromagnetic interference (EMI) protection when used with a corresponding connector housing that may require a specific shape, and further, unlike conventional ferrules and conventional stamped shields which may allow EMI leakage, when used with such a corresponding housing into which a wire or terminal is inserted, by covering the through-hole or aperture through which the wire or terminal is positioned, allows little or no leakage path for EMI.

[0014] The vertical disc ferrule of the present invention also limits the possibility of contact between the power circuit and the ground circuit during processing by providing sufficient clearance between the wire core or terminal (power circuit) and the wire braid shield or ferrule (ground circuit) and limiting the possibility of frayed wires in the wire braid shield contacting the power circuit. [Brief explanation of the drawings]

[0015] [Figure 1A] FIG. 1A is a side view of a connector assembly using a typical crimp ferrule and wire assembly in the related art. [Figure 1B] FIG. 1B is a perspective view of a typical crimp ferrule design with a flared portion in the related art. [Figure 2] FIG. 2 is a front view of the high voltage vertical disc ferrule of the present invention. [Figure 3] FIG. 3 is a perspective view of a high voltage vertical disc ferrule of the present invention using two high voltage vertical disc ferrules of the present invention fully assembled with wire. [Figure 4A] FIG. 4A is a side view of a high voltage vertical disk ferrule of the present invention assembled with a wire and a flared portion of the wire braid shield affixed to the front surface of the high voltage vertical disk ferrule. [Figure 4B]FIG. 4B is a side view of the high voltage vertical disk ferrule of the present invention assembled with a wire and a flared portion of the wire braid shield affixed to the rear face of the high voltage vertical disk ferrule. [Figure 4C] FIG. 4C is a side view of a high voltage vertical disc ferrule of the present invention using two high voltage vertical disc ferrules of the present invention with a wire. [Figure 4D] FIG. 4D is a side view of a high voltage vertical disk ferrule of the present invention fully assembled with a wire using two high voltage vertical disk ferrules of the present invention and soldered together. [Figure 5A] FIG. 5A is a side view of a high voltage vertical disc ferrule of the present invention fully assembled with a wire using two high voltage vertical disc ferrules of the present invention, the wire being inserted into a corresponding connector housing. [Figure 5B] FIG. 5B is a side view of a high voltage vertical disc ferrule of the present invention fully assembled with a wire using two high voltage vertical disc ferrules of the present invention, the wire being inserted into a corresponding connector housing. [Figure 5C] FIG. 5C is a side view of a high voltage vertical disc ferrule of the present invention fully assembled with a wire using two high voltage vertical disc ferrules of the present invention, the wire being inserted into a corresponding connector housing. [Figure 6A] FIG. 6A is a side view of a high voltage vertical disc ferrule of the present invention fully assembled with a wire using two high voltage vertical disc ferrules of the present invention, the wire being inserted into a corresponding connector housing. [Figure 6B] FIG. 6B is a side view of a high voltage vertical disc ferrule of the present invention fully assembled with a wire using two high voltage vertical disc ferrules of the present invention, the wire being inserted into a corresponding connector housing. [Figure 6C]FIG. 6C is a side view of the high voltage vertical disk ferrule of the present invention fully assembled with a wire using a single high voltage vertical disk ferrule of the present invention, with the flared portion of the wire braid shield affixed to the front face of the high voltage vertical disk ferrule and the wire fully inserted into the corresponding connector housing. [Figure 6D] FIG. 6D is a side view of the high voltage vertical disk ferrule of the present invention fully assembled with a wire using a single high voltage vertical disk ferrule of the present invention, with the flared portion of the wire braid shield secured to the rear face of the high voltage vertical disk ferrule and the wire fully inserted into the corresponding connector housing. [Figure 6E] FIG. 6E is a side view of the high voltage vertical disk ferrule of the present invention fully assembled with a wire using a single high voltage vertical disk ferrule of the present invention, with the flared portion of the wire braid shield secured to the front face of the high voltage vertical disk ferrule and the wire fully inserted into the corresponding connector housing with a spring acting on the ferrule. DETAILED DESCRIPTION OF THE INVENTION

[0016] FIG. 2 illustrates a high-voltage vertical-disk ferrule 100 of the present invention. The vertical-disk ferrule 100 can be made of any electrically conductive material, including, but not limited to, copper, tin-plated copper, steel, brass alloys, bronze, or any similar type of conductive metal known in metallurgy. The high-voltage vertical-disk ferrule 100 of the present invention comprises an outer edge 102, an inner edge 104 defining an aperture or through-hole 106, a planar front surface 108a, and a planar rear surface 108b. As shown more precisely in FIG. 3, the outer edge 102 and the front surface 108a are orthogonal to each other, and similarly, the outer edge 102 and the rear surface 108b are orthogonal to each other. The inner edge 104 and the front surface 108a are also orthogonal to each other, and similarly, the inner edge 104 and the rear surface 108b are also orthogonal to each other. Thus, as shown in FIG. 3A, the distance or length of the outer edge 102 and the inner edge in a direction parallel to the wire 200 or axially relative to the wire 104 defines the thickness or length of the high voltage vertical disc ferrule 100 of the present invention.

[0017] 2 also illustrates, but is not limited to, a rounded, circular vertical disk ferrule 100 of the present invention as a vertical disk-like structure. The disk-like structure is primarily comprised of vertical, flat surfaces on the front and rear faces 108a, 108b, and the boundaries, edges, or vertical shape defining the outer edge 102 are not necessarily formed to be rounded, and may have any shape that can be stamped. For example, the shape of the vertical disk ferrule 100 may be oval, elliptical, or any other shape permitted by the stamping means defining the outer edge 102. Preferably, the shape of the vertical disk ferrule 100 completely or substantially covers a corresponding hole or through-hole (not shown) in a connector housing through which an associated wire 200 or terminal 300 (see FIGS. 6A-6d) must be attached and pass when used with the vertical disk ferrule 100. Thus, the shape of the vertical disc ferrule 100 allows it to provide complete or substantial electromagnetic interference (EMI) suppression or coverage when used with a corresponding connector housing 400 (see FIGS. 6A-6D), which itself may require a particular shape to accommodate the vertical disc ferrule 100 in a recess or cavity (not shown).

[0018] As shown in FIG. 2 or 3 , the circular vertical disk ferrule 100 has its front face 108 a and rear face 108 b extending perpendicularly outward from its opening 106 and the respective wire 200 inserted therethrough. The wire is comprised of a wire core portion 204, a wire core insulation 206, a wire braid shield 202, and an outer wire insulation 208. As previously described, the front face 108 a and rear face 108 b of the vertical disk ferrule 100 are preferably generally perpendicular to the axial direction of the wire 200. The diameter or size of the front face 108 a and rear face 108 b is large enough for the vertical disk ferrule 100 to cover a hole in the respective housing 400 (see, e.g., FIGS. 5A-5C or 6A-6E ), which is large enough to accommodate the respective portions of the wire core 204 and / or wire core insulation 106, and the terminal 300. Thus, the sizes of the front face 108 a and rear face 108 b of the high-voltage vertical-disk ferrule 100 are not limited, but their respective sizes should be equal to or greater than the size of the outer insulation 208 of the wire 200, so that the vertical-disk ferrule 100 can have an inner edge 104 defining an opening 106 for the vertical-disk ferrule 100 that is appropriately sized for proper use with the size of the respective wire 200, while the vertical-disk ferrule 100 has appropriate surfaces on the front face 108 a and rear face 108 b for suitable grounding with grounding elements to function properly in use, and the wire 200 remains flexible behind the ferrule 100. The opening 106 of the high-voltage vertical-disk ferrule 100 is also sized to allow the high-voltage vertical-disk ferrule 100 to move freely over the wire braid shield 202 of the wire 200, as needed, as described below.

[0019] The high-voltage vertical-disk ferrules 100 contact their respective ground elements in their respective housings 400 (see FIGS. 5A-5C or 6A-6E) at their front vertical surfaces 108a, or in combination with their front vertical surfaces 108a and the wire braid shield 202 when used as a single ferrule 100 with the flared portion F of the wire braid shield 202 sandwiched therebetween. The ground elements in their respective housings 400 may be, for example, plated surfaces, conventional stamped shields, foil-backed surfaces, or other conductive materials utilized within, on, or by the housing 400 for grounding purposes. The outer edges 102 of the high-voltage vertical-disk ferrules 100 may also contact the ground elements of their respective metal connector housings 400, if desired.

[0020] The thickness of the high-voltage vertical-disk ferrule 100 in the axial direction is determined by the length of the outer edge 102, and is preferably 1 mm or less (although the size and / or length are not limited thereto); the preferred thickness of the high-voltage vertical-disk ferrule 100 in the axial direction is maintained thin enough to reduce the space required in the respective connector housing compared to conventional crimp ferrules, is thinner or shorter than conventional crimp ferrules, and allows for proper winding of the wire 200, as described further below. The thickness of the high-voltage vertical-disk ferrule 100 is further preferably such that the high-voltage vertical-disk ferrule 100 is accommodated within a recess in each housing 400 so that the high-voltage vertical-disk ferrule 100 resides within a portion of each housing 400 as needed, thereby providing the housing 100 with a design that is much shorter than conventional ferrules required by assembly methods. The high-voltage vertical-disk ferrule 100 may also be accommodated outside each housing 400 by substantially abutting a surface or side of the housing 400 (see FIGS. 6A, 6B, and 6D).

[0021] As shown in Figure 4A, the vertical disk ferrule 100 is disposed along the wire braided shield 202 of the wire 200. As described above, the front face 108a and rear face 108b of the vertical disk ferrule 100 are preferably substantially perpendicular to the axial direction of the wire 200. Therefore, the braided shield portion 202 can be secured to the front face 108a by forming a flared portion F that radiates forward of the core insulator 206 that is substantially perpendicular to the longitudinal direction of the wire 200, thereby flaring outward (see also Figure 6A).

[0022] Similarly, in FIG. 4B, the flared portion F of the braided shield portion 202 can also be secured to the rear face 108b of the vertical-disk ferrule 100 (see also FIG. 6D). Both structural arrangements or methods allow the wire braided shield portion 202 of the wire 200 to be secured so that the wire shield 202 is in conductive electrical contact with the front face 108a or rear face 108b of the vertical-disk ferrule 100. Advantageously, however, the wire braided shield 202 does not require a secondary cut if it is positioned radially away from, and does not extend beyond, the face of the front face 108a or rear face 108b of the vertical-disk ferrule 100, regardless of whether a single vertical-disk ferrule 100 or two vertical-disk ferrules 100 are used.

[0023] In the assembly method of the present invention, in which the wire 200 is pushed through the vertical-disk ferrule 100, this method pushes back the wire braid shield 202, allowing the wire braid shield 202 to generate a natural spring force against the vertical-disk ferrule 100 (or the rearmost vertical-disk ferrule 100, if two vertical-disk ferrules 100 are used), causing the wire braid shield 202 to assume a bellows, pleats, or folded state or condition against itself (see FIG. 5C ), thus pushing back in the direction in which the vertical-disk ferrule 100 moved along the wire core 204 as the wire 200 was being pushed, pushing the vertical-disk ferrule 100 forward (or toward the cut end of the attached wire 200 or terminal 300). This force allows the high-voltage vertical-disk ferrule 100 and / or the wire braid shield 202 to remain in contact with the ground structure of the connector housing 400, if any, between the vertical-disk ferrule 100 and the connector housing 400. If a single vertical disc ferrule 100 is used, this force pushes the vertical disc ferrule 100 against the wire braid shield 202 which abuts the ground element or housing 400 .

[0024] 4C or 4D shows a preferred use of two vertical-disc ferrules 100. By using two vertical-disc ferrules 100, a first vertical-disc ferrule 100a and a second vertical-disc ferrule 100b, the wire braid shield 202 of the wire 200 can be sandwiched between the front face 108a of the first vertical-disc ferrule 100a and the rear face 108b of the second vertical-disc ferrule 100b. The first vertical-disc ferrule 100a is positioned around the wire braid shield portion 202 as shown in FIG. 4C, so that the flared portion F of the wire braid shield 202 is then contacted by the front face 108a of the first vertical-disc ferrule 100a, and then the rear face 108b of the second vertical-disc ferrule 100b contacts the flared portion F when inserted, ultimately surrounding the wire core insulation 206 and preferably not contacting the wire core 204 during use (see FIGS. 6A and 6B). The above-described structural arrangement provides proper contact between the flared portion F of the wire braided shield 202 and the first and second vertical disc ferrules 100a, 100b, and also provides proper continuity from both vertical disc ferrules 100 to the wire braided shield 202 during use. Solder (shown as S) or other mechanical or electromechanical means may be used to further stabilize or facilitate the clamping or insertion of the flared portion F of the wire braided shield 202 and to ensure the structural arrangement or relationship of these components for complete continuity, as further described below.

[0025] When using two vertical-disc ferrules 100, it is additionally or optimally desirable to securely fasten the two vertical-disc ferrules 100 to one another to hold and maintain the wire braid shield 202 sandwiched and inserted between them, as described above. To ensure proper operation of the two vertical-disc ferrules 100, mechanical or electromechanical means are preferably used to connect the two vertical-disc ferrules 100. For example, soldering (as shown by reference character S in FIG. 4D ), welding (resistance, spot, ultrasonic, etc.), or brazing are electromechanical methods that can be used to connect the respective metals that make up the two vertical-disc ferrules 100. Mechanical joining using press fits or snap fits may also be used. As shown in FIG. 4D , solder S is applied to secure the first vertical-disc ferrule 100a and the second vertical-disc ferrule 100b to one another and to provide a means for securing the wire braid shield 202 therebetween. The means for securing the two vertical disc ferrules 100 together provides and facilitates a suitable conductive and / or physical substrate for connecting the second vertical disc ferrule 100b to the first vertical disc ferrule 100a, thus ensuring a conductive connection and contact to the wire braid shields 202 of the two vertical disc ferrules 100 when or if the second vertical disc ferrule 100b contacts a ground structure within the corresponding housing 400. Furthermore, if a single vertical disc ferrule 100 is used, the wire braid shield 202 and the vertical disc ferrule 100 may be soldered together to ensure that they are fixed and secured together (soldered to either the front face 108a or the rear face 108b) and that they move synchronously together as a unit (see FIGS. 5A-5C or 6A-6B).

[0026] 6A and 6B illustrate the use of a terminal 300 on a wire 200. The terminal 300 is secured to the end of the wire 200 by being secured (e.g., soldered) to the wire core portion 204 of the wire 200. While FIG. 6A illustrates the use of two vertical disc ferrules 100, FIGS. 6C and 6D are not so limited; the replacement and use of a single vertical disc ferrule 100 is equally applicable to the structures, structural arrangements, or methods of the present invention, as shown and further described below. For example, when two vertical disc ferrules 100 are used, one is mounted around the wire shield 202 (first vertical disc ferrule 100a) and the other (second vertical disc ferrule 100b) is mounted around the core insulator 206. When a single vertical disc ferrule 100 is used and the wire shield 202 is secured to or facing the front face 108a of the vertical disc ferrule 100, the vertical disc ferrule 100 is placed around the wire shield 202. Additionally, when a single vertical disc ferrule 100 is used and the wire shield 202 is secured to or facing the rear face 108b of the vertical disc ferrule 100, the vertical disc ferrule is placed around the wire core insulation 206.

[0027] As shown in FIG. 6A , the wire braid shield portion 202 of the wire 200 is secured between two vertical disk ferrules 100. Because the wire shield 202 is fully extended in a direction such that a portion of the wire shield 202 lies flat along the insulation 206 of the core portion 204 and the flared end F of the wire braid shield portion 202 is fixed and moves forward between the two vertical disk ferrules 100, the vertical disk ferrules 100 cannot move axially along the wire 200 toward the terminal 300. However, the two vertical disk ferrules 100 can move axially toward the vertical plane of the outer wire insulation portion 208 and away from the cut end of the wire 200 or attached terminal 300. A first vertical disk ferrule 100 a is placed around the wire shield 202, and a second vertical disk ferrule 100 b is placed around the core insulator 206. In this method of the present invention, the wire 200 extends through the openings 106 of both vertical-disk ferrules 100 during what is considered a "take-up," which includes bunching or corrugating (A) of the wire shield 202, due to slack or tolerance for movement of the wire core 204 as it further relates to the exposed length of the shield 202 (see also FIGS. 5A and 5B). The shield 202 is bunched on the side of the two vertical-disk ferrules 100 opposite the side from which the terminal 300 and wire core 204 extend. As the two vertical-disk ferrules 100 move parallel to the wire 200 along the axial direction of the wire 200, the wire core 204 moves along and through the openings 106 of the two vertical-disk ferrules 100. As a result, the wire braid shield portion 202 bunches or corrugates upon itself, as indicated by reference letter A, as the "take-up" of the wire 200 occurs. The wire braid shield 202 is bundled from the exposed portion of the outer insulation 208 of the wire 200 to a point where it can contact the rear face 108 b of the first vertical disc ferrule 100 .As shown in Figure 6B, after the wire braided shield portion 202 is bunched or corrugated, the bunched or corrugated portion A of the wire shield 202 exerts a force against the rear surface 108b of the vertical-disk ferrule 100. This is because the wire braided shield 202 is pressed against itself and becomes compressed while being pushed up against the vertical-disk ferrule 100. Therefore, as shown in Figures 5A and 5B, this corrugated portion A of the wire braided shield portion 202 exerts a spring-like force against the vertical-disk ferrule 100a when the wire 200 is in this state. The force provided by the wire shield 202 provides or ensures that the second vertical disc ferrule 100b is pressed against at least one of the surface of the housing 400 and the respective shielding means incorporated into the connector housing 400, and the second vertical disc ferrule 100b also properly covers the opening or through-hole (not shown) in the housing 400 (see, for example, Figures 5C, 6A and 6B).

[0028] 6B also illustrates the complete extension or exposure of the wire core portion 204 from the wire braid shield 202, where the wire core portion 204 moves through the opening 106 of the vertical disk ferrule 100, allowing the wire core portion 204 and terminal 300 to extend away from the vertical disk ferrule 100, reaching a point where the "rolling up" process can be fully completed. The wire core portion 204 and its insulation 206 are moved along the axial direction of the wire 200 through the openings 106 of the two vertical disk ferrules 100, as previously described. The wire braid shield 202 is fixed between the two vertical disk ferrules 100, so that the bundled or corrugated portion A of the wire braid shield 202 is adjusted when the outer insulation 208 of the wire 200 moves toward the two vertical disk ferrules 100 in conjunction with movement of the wire 200 into the housing 400, and when one of the vertical disk ferrules 100 abuts the housing 400 or when the two vertical disk ferrules 100 are fixed in some other way. Similarly, the wire braid shield 202 is bundled or corrugated in the space between the vertical disk ferrules 100 and the outer insulation 208, so that the exposed portion of the wire braid shield 202 extends along the wire core insulation 206 and the end (flared portion F) is between the two vertical disk ferrules 100.

[0029] 6B, extension of terminal 300 into housing 400 is limited by front stop F, which is a surface or feature on housing 400 that limits movement of terminal 300 into housing 400 while terminal 300 is being pushed or inserted into housing 400. When terminal 300 contacts or abuts front stop F, terminal 300 is also preferably secured or immobilized between housing 400 and terminal 300 by means of securing, locking, or fastening terminal 300 to housing 400. The secured, locked, or fastened terminal 300 ensures that terminal 300 and attached wire core portion 204 are prevented or inhibited from inadvertently extending or being removed from housing 400 in a direction opposite to the insertion direction of terminal 300 (see FIG. 6B). The above-described structural arrangement or assembly method of the present invention further ensures that the bellows A state of the wire braided shield portion 202 is maintained, which state exists when the terminal 300 is in the forward-most or locked position. Furthermore, by ensuring that the terminal 300 and wire core portion 204 do not move in a direction opposite to the insertion of the terminal 300 into the housing 400, it ensures that sufficient force from the bellows A is subsequently applied to the two vertical-disk ferrules 100 in a spring-like manner and does not subsequently decrease, so that the second vertical-disk ferrule 100 maintains contact with the housing 400 and contacts its respective gland structural arrangement or feature. If the terminal 300 and wire core portion 204 can be removed or removed from the housing 400, the bundled or bellows A portion of the wire braided shield 202 may not be maintained if the wire core portion 204 slides or moves backward or in a direction opposite to the mating of the terminal 300 and the terminal 300 itself or the housing 400 itself. Therefore, when the wire core portion 204 slides or moves in the opposite direction through the opening 106 of the vertical disc ferrule 100, extending or retracting the wire braided shield 202 in the axial direction of the wire 200 to the relaxed state before the terminal 300 is inserted does not provide a proper bellows A state.6A, the bellows A state seen in FIG. 6B no longer exists. Therefore, after the vertical disc ferrule 100 contacts the housing 400, fixation by the housing 400 or between the housing 400 and the terminal 400 is preferably achieved, and thus the braided shield portion 202 provides a spring-like force against the portion of the vertical disc ferrule 100 opposite the portion of the vertical disc ferrule 100, or against an additional vertical disc ferrule 100 contacting the housing, to further maintain contact between the vertical disc ferrule 100 and the housing and the arrangement or characteristics of their respective gland structures.

[0030] 6C , the flared portion F of the wire braid shield 202 of the wire 200 is secured to the front surface 108a of the single vertical disk ferrule 100. Once the flared portion F of the wire braid shield 202 is attached, the vertical disk ferrule 100 cannot move further forward in the axial direction along the wire 200 toward the terminal 300 because a portion of the wire shield 202 is fully extended in the direction shown and flattened along the wire core insulation 206 of the core portion 204, and the flared end F of the wire braid shield 202 is secured and fixed to prevent movement from its position on the vertical disk ferrule 300, and may be further secured to the front surface 108a of the vertical disk ferrule 100 using solder. Furthermore, the wire braid shield 202 does not have to be secured or fixed to the vertical disk ferrule 100, but may move away from the flared portion F of the braid shield portion 202 as well. However, with the wire shield 202 secured, the single vertical disk ferrule 100 is movable axially toward the vertical portion of the outer wire insulation 208 and away from the cut end of the wire or attached terminal 300. Thus, when the single vertical disk ferrule 100 is used and the wire shield 202 is secured to or facing the front surface 108a of the vertical disk ferrule 100, the vertical disk ferrule 100 rests around the wire shield 202. In this method of the present invention, the wire extends through the opening 106 of the vertical disk ferrule 100 during what is considered "rolling," which includes bundling or corrugating portion A of the wire shield 202, due to slack or tolerance for movement of the wire core 204 as it further relates to the exposed length of the shield 202. The shield 202 is bundled on the side of the vertical disc ferrule 100 opposite the front face 108a of the vertical disc ferrule 100 from which the terminal 300 and the wire core 204 extend.As the vertical-disk ferrule 100 moves axially along the wire 200, along the wire braid shield 202, and parallel to the wire 200, the wire core 204 moves along and through the opening 106 of the vertical-disk ferrule 100. As a result, the wire braid shield 202 bunches or corrugates onto itself, as indicated by reference letter A, as the "roll-up" of the wire 200 occurs. The wire braid shield 202 bunches from where it is exposed at the outer insulation 208 of the wire 200 to where it may contact the rear face 108b of the second vertical-disk ferrule 100. After the wire braid shield 202 has bunched or corrugated, as at portion A thereof, as shown in FIG. 6C, this portion A of the wire shield 202 exerts a force against the rear face 108b of the vertical-disk ferrule 100. This is because the wire shield 202 is pressed against itself and compressed while abutting against the vertical-disk ferrule 100. More specifically, by bundling or corrugating the wire braid shield 202 in the space between the vertical-disk ferrule 100 and the outer insulator 208, the exposed portion of the wire braid shield 202 extends along the wire core insulator 206, with the end (flared portion F) positioned between the vertical-disk ferrule 100 and the housing 400. Therefore, this corrugated portion A of the wire braid shield 202 applies a spring-like force to the vertical-disk ferrule 100 when the wire 200 is in this state. The spring force provided by the wire braided shield 202 provides or ensures that the front surface 108a of the vertical disc ferrule 100 is pressed into contact with the flared portion F of the wire braided shield 202, or if the wire braided shield 202 is further fixed or soldered, ensures that the wire shield 202 is pressed into contact with the surface of the housing 400 and the interior of the housing 400, or any such respective shielding means (not shown) therein, and the vertical disc ferrule 100 also properly covers any openings or through holes (not shown) in the housing 400.

[0031] 6D , the flared portion F of the wire braid shield 202 of the wire 200 is secured to the rear surface 108b of the single vertical disc ferrule 100. Once the flared portion F of the wire braid shield 202 is attached, the vertical disc ferrule 100 cannot move further forward in the axial direction along the wire 200 toward the terminal 300 because a portion of the wire shield 202 is fully extended in the direction shown and flattened along the insulation 206 of the core portion 204, and the flared end F of the wire braid shield 202 is secured and fixed to prevent movement from its position on the vertical disc ferrule 300, and may be further secured to the rear surface 108b of the vertical disc ferrule 100 using solder. Furthermore, the wire braid shield 202 does not have to be secured or fixed to the vertical disc ferrule 100, but may move away from the flared portion F of the braid shield portion 202 as well. However, with the wire shield 202 secured, the single vertical disk ferrule 100 is movable axially toward the outer wire insulation 208 and away from the cut end of the wire or attached terminal 300. Thus, when the single vertical disk ferrule 100 is used to secure the wire braid shield 202 or place it against the rear face 108b of the vertical disk ferrule 100, the vertical disk ferrule 100 rests around the wire core insulation 206 and not around the wire braid shield 202. During this process, the wire 200 extends through the opening 106 of the vertical disk ferrule 100 during what is considered "rolling," which includes bundling or corrugating (A) of the wire shield 202, due to slack or tolerance for movement of the wire core 204 as it relates to the exposed length of the shield 202. The shield 202 is bundled on the side of the vertical disc ferrule 100 opposite the front face 108a of the vertical disc ferrule 100 from which the terminal 300 and the wire core 204 extend.As the vertical-disk ferrule 100 moves axially along the wire 200, along the wire core insulation 206, and parallel to the wire 200, the wire core 204 moves along and through the opening 106 of the vertical-disk ferrule 100. As a result, the wire braid shield portion 202 bunches or corrugates on itself, as indicated by reference letter A, as "rolling up" of the wire 200 occurs. The wire braid shield 202 bunches from where it is exposed at the outer insulation 208 of the wire 200 to where it may contact the rear face 108b of the second vertical-disk ferrule 100. As further shown in FIG. 6D , after the wire braid shield 202 bunches or corrugates (as at portion A of the wire shield 202), this portion A of the wire shield 202 exerts a force against the rear face 108b of the vertical-disk ferrule 100. This causes the wire shield 202 to be pressed against itself and compressed while abutting against the vertical disk ferrule 100. Thus, more specifically, whether the wire braid shield 202 is bunched or concertinaed in the space between the vertical disk ferrule 100 and the outer insulator 208, the exposed portion of the wire braid shield 202 extends along the wire core insulator 206, with the end (flared portion F) located between the vertical disk ferrule 100 and the concertina portion A. This concertina portion A of the wire braid shield 202 therefore exerts a spring-like force against the vertical disk ferrule 100 when the wire 200 is in this state. The spring force provided by the wire shield 202 provides or ensures that the front surface 108a of the vertical disc ferrule 100 is pressed into contact with the surface of the housing 400 and the interior of the housing 400, or any such respective shielding means (not shown) therein, and the vertical disc ferrule 100 also properly covers an opening (not shown) in the housing 400.

[0032] The structural arrangement and method of the vertical disk ferrule 100 of the present invention also increases electrical clearance during operation. In other words, by having the vertical disk ferrule 100 and wire braid shield 202 (ground circuitry) further away from the terminal 300 or wire core 204 (power circuitry) as a result of the wire 200 moving further into the connector housing 400, and by having the terminal 300 or wire core 204 extend further away from the vertical disk ferrule 100, electrical clearance is increased from these two components compared to conventional ferrule structural arrangements and assemblies having conventional ferrules closer to the attached terminals.

[0033] The inventive high voltage vertical disk ferrule 100 and its assembly method also eliminate the possibility of frayed wires from the braided shield 202 (ground circuitry) coming into contact with the power circuitry (wire core 204) during operation. The flared portion F of the inventive wire braided shield 202, when used with the inventive vertical disk ferrule 100, is substantially vertical and is "pulled back" away from the wire core insulation 208 and wire core 204, so that, as previously explained, any frayed wires of the wire braided shield 202 advantageously do not come into close proximity with the power circuitry when the inventive high voltage vertical disk ferrule 100 is used.

[0034] Another option is to use a spring S, as shown in Figure 6E. The spring S is supported by a cap (the portion surrounding the spring) at one end of the housing 400 and applies a spring force against the rear surface 108b or rear surface 108b of the vertical disc ferrule 100, ensuring that the vertical disc ferrule 100 abuts the braided shield portion 202 and the housing 400. This structural arrangement, shown in Figure 6B, allows the spring S to complement the spring force generated by the compression of the wire braided shield 202 during its operation.

[0035] It should also be noted that while the above description is of a preferred embodiment of the present invention, other modifications and variations will be apparent to those skilled in the art and may be implemented without departing from the spirit of the invention. Furthermore, structural arrangements or features described in connection with one embodiment of the present invention may be employed with other embodiments, even if not explicitly described above.

Claims

1. A structure including a high voltage vertical disc ferrule and a wire passing through the high voltage vertical disc ferrule for use with a corresponding connector housing requiring electromagnetic interference (EMI) protection, said high voltage vertical disc ferrule The front and The rear and The outer edge and an opening; The front surface is a flat surface, The rear surface is a flat surface, The wire Wire shielding and an outer insulator; The wire shield located between the rear surface and the outer insulation of the wire has a bundled or bellows-shaped deformed portion formed thereon, The outer edge defines a thickness of the high voltage vertical disk ferrule.

2. The structure of claim 1 , wherein said front surface is substantially perpendicular to said outer edge.

3. The structure of claim 1 , wherein said rear surface is substantially perpendicular to said outer edge.

4. inserting at least one high voltage vertical disc ferrule having a planar front surface, a planar rear surface, an outer edge, and an opening around a wire shield of the wire; pressing an end portion of the wire shield against at least a flat surface of the at least one high voltage vertical disk ferrule to form a flared portion of the end portion of the wire shield; forming a bundled or bellows-like portion in a wire shield located between the at least one high voltage vertical disk ferrule and an outer insulation of the wire.

5. 5. The method of assembling a high voltage vertical disk ferrule and a wire as defined in claim 4, wherein the step of inserting the high voltage vertical disk ferrule around the wire shield includes positioning the at least one high voltage vertical disk ferrule substantially perpendicular to the wire.

6. 5. The method for assembling a high voltage vertical disk ferrule and a wire as recited in claim 4, wherein the step of inserting the at least one high voltage vertical disk ferrule includes one of the steps of pressing the at least one high voltage vertical disk ferrule against an end portion of the wire shield and pressing the end portion of the wire shield against the at least one high voltage vertical disk ferrule.

7. pressing an end portion of the wire shield of the wire into a flared shape; inserting a high voltage vertical disc ferrule having a flat front surface, a flat rear surface, an outer edge, and an opening around a wire core insulation of the wire; pressing at least a portion of the flat surface of the high voltage vertical disk ferrule against the flared portion of the end portion of the wire shield; positioning the high voltage vertical disk ferrule perpendicular to the wire; forming a bundled or bellows-like portion in the wire shield located between the high voltage vertical disk ferrule and the outer insulation of the wire.

8. 8. The method of assembling a high voltage vertical disk ferrule and wire as defined in claim 7, wherein the step of inserting the high voltage vertical disk ferrule around the wire core insulation includes positioning the high voltage vertical disk ferrule substantially perpendicular to the wire.

9. a first high-voltage vertical disk ferrule and a second high-voltage vertical disk ferrule, each of which is the high-voltage vertical disk ferrule; the first high voltage vertical disc ferrule includes a first front face and a first rear face; the second high voltage vertical disc ferrule includes a second front face and a second rear face; 2. The structure of claim 1, wherein said first front face of said first high voltage vertical disk ferrule faces said second rear face of said second high voltage vertical disk ferrule.

10. 10. The structure of claim 9, wherein the first front face of the first high voltage vertical disk ferrule and the second rear face of the second high voltage vertical disk ferrule sandwich a wire braid shield of a wire shield of a wire to which the high voltage vertical disk ferrule is connected.

11. 11. The structure of claim 10, wherein the wire braid shield of the wire is soldered, mechanically bonded, or electromechanically bonded to the first high voltage vertical disk ferrule and the second high voltage vertical disk ferrule.

12. inserting the at least one high voltage vertical disc ferrule around a wire shield of a wire, (a) inserting a first high voltage vertical disc ferrule around the wire shield of the wire; (b) pressing the end portion of the wire shield against the first high-voltage vertical disk ferrule, or pressing the first high-voltage vertical disk ferrule against the end portion of the wire shield; (c) inserting a second high voltage vertical disc ferrule around the wire core insulation of said wire; 5. The method of claim 4, further comprising the step of: (d) pressing said second high voltage vertical disk ferrule against said end portion of said wire shield.

13. 13. The method of assembling a high voltage vertical disk ferrule and a wire as recited in claim 12, further characterized by the step of sandwiching a flared portion of the wire shield of the wire between the first high voltage vertical disk ferrule and the second high voltage vertical disk ferrule.

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