Cable Fixation Shell with Inner Protrusions for Orientation

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Solution Overview

Problem

Existing cable connection systems face issues with terminal orientation variability, inadequate cable fixation, and increased costs due to the need for different ferrules for varying cable diameters, which results in inefficient and costly crimping processes.

Innovation Solution

A cable connection system utilizing a closable plastic shell with inner protrusions to securely fix the cable, allowing for proper orientation and attachment of the housing, reducing the need for metal crimp ferrules and advanced crimping equipment, and enabling secure cable fixation without requiring complex orientation alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal crimp ferrules are used for cable fixation, then cable pulling strength is improved, but device complexity and manufacturing cost increase due to needing different ferrules for different cable diameters

Engineering Contradiction:

Improvecable pulling strengthVSAvoidferrule variety

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The plastic shell is designed with a universal structure that can accommodate different cable diameters through its elastic deformation capability. The shell maintains a consistent design across all cable sizes, eliminating the need for multiple specialized ferrules while providing adequate fixation strength for various cable dimensions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The plastic shell utilizes material elasticity and dimensional flexibility to adapt to different cable diameters. By changing the shell's inner diameter parameter across different size variants rather than changing the entire ferrule structure, the system achieves universality while maintaining fixation strength.

Inventive Principle:

Principle #35Parameter changes

2Strength

If metal crimp ferrules are used for cable fixation, then cable pulling strength is improved, but ease of manufacture deteriorates due to requiring advanced crimping equipment

Engineering Contradiction:

Improvecable pulling strengthVSAvoidcrimping process simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention replaces the mechanical crimping process with a simple insertion and clipping mechanism. The plastic shell is inserted over the cable and fixed using clips or snap-fit features, eliminating the need for specialized crimping tools and complex mechanical deformation processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The plastic shell is designed as a low-cost, single-use component that is discarded if improper orientation is detected. This approach prioritizes ease of manufacture and quality control over component reuse, allowing for simpler manufacturing processes and better orientation verification.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If terminals are not orientation-fixed, then adaptability is improved, but manufacturing precision deteriorates due to incorrect terminal orientation relative to housing

Engineering Contradiction:

Improveterminal orientation flexibilityVSAvoidterminal orientation accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The plastic shell is designed with built-in orientation features such as asymmetric clips, keyed interfaces, or positional markers that guide the cable and terminal into the correct orientation before housing assembly. This preliminary orientation action prevents incorrect installation while maintaining ease of assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The shell incorporates asymmetric features such as non-uniform clip positions, uneven rib distributions, or directional markings that create a unique correct orientation. These asymmetric elements naturally guide proper alignment during assembly without requiring complex alignment procedures.

Inventive Principle:

Principle #4Asymmetry

4Strength

If crimp metal ferrules are used, then cable fixation in one direction is improved, but reliability deteriorates because fixation strength in cable pushing direction is insufficient

Engineering Contradiction:

Improvecable fixation strength in pulling directionVSAvoidbidirectional fixation reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The fixation system is segmented into multiple independent elements including clips, ribs, and engagement features distributed around the shell's circumference. These segmented elements work together to provide fixation in multiple directions, with each element contributing to both pulling and pushing resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fixation mechanism transitions from unidirectional crimping to multi-directional engagement through features like circumferential clips, axial ribs, and radial engagement points. This dimensional expansion of fixation capability provides balanced strength in both pulling and pushing directions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP3570387B1Cable connection system with cable fixation shell

Publication Date: 2022.02.09 APTIV TECHNOLOGIES LTD

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AI summary

The present invention relates to a cable connection system. The cable connection system thereby comprises a cable having an insulation sleeve, a shell encompassing the cable and having inner protrusions for fixing the shell to the insulation sleeve of the cable, and a housing attached to the shell. The application further relates to a method of assembling such a cable connection system, the use of such a cable connection system, as well as a shell for attaching a housing to a cable.