Cable Assembly Outer Ferrule Shielding and Sealing
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Solution Overview
Problem
Existing cable assemblies face challenges in maintaining shielding continuity and water-tightness in high-voltage applications, particularly due to unstable electrical connections between the outer ferrule and the outer electromagnetic shield, which are exacerbated by environmental factors like humidity and dust.
Innovation Solution
A cable assembly design featuring an outer ferrule with a distal end directly connected to the outer electromagnetic shield, stabilized by a pusher mechanism with ribs, and sealed with insulating annular seals to ensure both electrical stability and water-tightness, even under vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If an electrically conductive seal is used to connect the outer ferrule to the outer electromagnetic shield, then the number of pieces is reduced, but the electrical connection becomes unstable
Solution Approach 1:
The solution divides the sealing and connection function into two separate components: an electrically insulating seal for water-tightness and an electrically conductive element for stable electrical connection. This segmentation allows each component to optimize its specific function without compromise, resolving the contradiction between reducing piece count and ensuring connection stability.
Solution Approach 2:
The patent introduces an electrically insulating seal as an intermediary element between the outer ferrule and the outer electromagnetic shield. This intermediary provides water-tightness while allowing a separate conductive path to maintain stable electrical connection, effectively mediating between the conflicting requirements of simplicity and reliability.
2Object-affected harmful factors
If shielding continuity and water-tightness are both required in the electrical connector, then protection against environmental factors is improved, but manufacturing and mounting become more difficult
Solution Approach 1:
The patent merges the water-tight sealing function and the electrical connection function into a single integrated assembly where the electrically insulating seal and conductive element work together. This merging maintains comprehensive protection against environmental factors while simplifying the manufacturing process by eliminating the need for separate conductive seals and reducing assembly steps.
Solution Approach 2:
The use of electrically insulating material for both the seal and housing creates material homogeneity in the non-conductive portions, simplifying manufacturing processes and material selection while maintaining both shielding continuity through the separate conductive element and water-tightness through the seal.
Data Source
Figure 1~4
Figure 5~7
AI summary
The cable assembly comprises : - an electrical connector (6) having an inner housing (36) with a cavity (40) in which is receive a cable (4) tip, - an outer ferrule (72) comprising a distal end (76) that extends beyond an aperture (46) of the cavity and that comes in direct mechanical and electrical contact with an outer electromagnetic shield (38), - an outer annular seal (100) interposed between an outward face of the outer ferrule and an inward face of the inner housing to ensure water-tightness between the outer ferrule and the inner housing, and - an inner annular seal (102) interposed between an inward face of the outer ferrule and an outer insulative sheath (12) of the cable (4) to ensure water-tightness between the outer ferrule and the cable.