Angled Harness Assembly with Nested Braids for EMI Shielding
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Solution Overview
Problem
Cable designs for harness assemblies, such as those connecting sensors in vehicle engines, face challenges in minimizing electromagnetic interference (EMI) while balancing factors like pull strength, strain relief, environmental sealing, and manufacturing ease, with existing solutions often compromising on weight and cost.
Innovation Solution
A harness assembly featuring a cable with angled integrated backshell, an external braid, and an overbraid with two layers, providing enhanced EMI shielding and reduced weight and cost through a double layer configuration, along with secure connections and environmental protection using Teflon tubing and heat shrink boots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional single-layer braid and shield configurations are used, then manufacturing simplicity is maintained, but EMI shielding effectiveness is insufficient
Solution Approach 1:
The patent implements a nested shielding structure where an inner braid layer is positioned inside the cable assembly and an outer braid layer is positioned outside the cable assembly, with both layers nested concentrically around the conductors. This nested configuration provides enhanced EMI shielding effectiveness while maintaining a compact overall structure.
Solution Approach 2:
The patent uses a composite shielding approach combining two different braid materials with distinct properties: an inner braid layer made of one material type and an outer braid layer made of another material type. This composite structure leverages the complementary advantages of different materials to achieve superior EMI shielding performance.
2Object-affected harmful factors
If additional shielding layers and components are added to reduce EMI, then EMI protection is improved, but weight and cost increase
Solution Approach 1:
The nested braid configuration allows both inner and outer braid layers to be positioned concentrically around the conductors, maximizing shielding effectiveness while minimizing the radial space required. This compact nested arrangement reduces the overall volume and weight of the shielding structure compared to alternative configurations.
Solution Approach 2:
The patent employs flexible braid constructions that can conform to the cable geometry, allowing thin yet effective shielding layers to be applied. The braid structure provides adequate EMI protection with minimal material thickness, thereby reducing weight while maintaining shielding performance.
3Object-affected harmful factors
If complex multi-layer braid structures are implemented, then EMI shielding is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
The nested braid structure is designed to be applied in a sequential manner during the cable manufacturing process, where the inner braid is applied first followed by the outer braid. This sequential application method simplifies the manufacturing process compared to attempting to apply multiple layers simultaneously, making the complex structure easier to manufacture.
Solution Approach 2:
The patent incorporates the inner braid layer as part of the cable construction before the final assembly is completed. By pre-applying the inner braid during cable manufacturing and then adding the outer braid in a subsequent step, the complex multi-layer structure is broken down into manageable preliminary actions that simplify overall manufacturing.
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
The solution effectively minimizes EMI, enhances strain relief, and reduces weight and cost by utilizing a double layer overbraid configuration and secure braid connections, while maintaining environmental protection and ease of assembly.
Implementation Method 1
cable shielding around at least a portion of a plurality of wires... external braid disposed around at least a portion of the backshell and the cable
Implementation Method 2
overbraid around at least a portion of the external braid, the overbraid having two layers
Implementation Method 3
environmental sealing... Teflon tubing and heat shrink boots
Data Source
AI summary
A harness assembly may include a cable having a cable shielding around at least a portion of a plurality of wires, a connector with an integrated backshell arranged at an angle with respect to the cable, an external braid disposed around at least a portion of the backshell and the cable, and an overbraid around at least a portion of the external braid, the overbraid having two layers.