Cable Harness Shielding with Curable Liquid Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable harnesses with electrical shielding face challenges in providing an effective shielding effect while maintaining ease of handling, especially in transition areas between electrical lines and connection elements, and are prone to interference emissions in harsh environments.
Innovation Solution
A cable harness element with two or more electrical conductors and connection elements, where the transition areas between the conductors and connection elements are surrounded by a tubular electrical shielding element wetted with a curable liquid to form a dimensionally stable module, ensuring electrical connectivity and improved shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a total shield surrounds multi-phase cables, then shielding effectiveness is improved, but handling properties deteriorate due to reduced flexibility
Solution Approach 1:
The patent divides the cable structure into segments: individually shielded cables bundled within a total shield. This segmentation allows each cable to maintain its flexibility while the total shield provides comprehensive protection, resolving the contradiction between shielding effectiveness and handling properties.
Solution Approach 2:
The patent implements a nested structure where individually shielded cables are placed inside a total shield. This nested arrangement allows the inner cables to move independently (maintaining flexibility) while the outer total shield provides continuous shielding (maintaining electromagnetic protection).
2Ease of operation
If individually shielded cables are used, then handling properties are improved, but high-frequency shield currents increase causing interference emissions
Solution Approach 1:
The patent combines individually shielded cables into a single bundle surrounded by a total shield. The individual shields handle high-frequency currents locally, while the total shield provides a common reference potential and contains any residual emissions, thus merging the benefits of both shielding approaches.
Solution Approach 2:
The total shield acts as a common equipotential surface for all individually shielded cables. By providing a shared reference potential, the total shield prevents potential differences between individual shields that would otherwise cause capacitive coupling and interference emissions.
3Ease of manufacture
If transition areas are left open without shielding, then ease of installation is improved, but shielding effectiveness deteriorates at connection points
Solution Approach 1:
The patent applies curable liquid sealing material in advance to the transition areas before final assembly. This preliminary action ensures that when connectors are installed, the shielding is already in place, maintaining both ease of installation and shielding effectiveness.
Solution Approach 2:
The curable liquid sealing material acts as an intermediary substance that bridges the gap between the shielded cable and the connector. It provides both mechanical sealing and electrical continuity, allowing easy installation while maintaining shielding effectiveness at the transition point.
4Reliability
If curable liquid is applied to transition areas, then shielding effectiveness and environmental protection are improved, but manufacturing complexity increases
Solution Approach 1:
The curable liquid sealing material is applied in a way that allows it to self-level and self-seal the transition areas. Once applied, the material cures automatically (or with minimal activation), providing both shielding continuity and environmental protection without requiring complex additional manufacturing steps.
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 enhances the shielding effect, improves handling properties, and provides increased resistance to mechanical stresses and environmental interference, leading to a longer service life and easier installation, especially in difficult-to-access locations.
Implementation Method 1
At least in the transition area, the electrical shielding elements are wetted with a curable liquid or are wholly or partially embedded therein, so that the electrical shielding element forms a dimensionally stable module after the curable liquid has cured.
Data Source
Figure 1a~1e
Figure 2~3
Figure 4~5
AI summary
A cable harness element (100) comprises two or more electrical conductors (102) and connected terminal elements (105). At least the transition areas between a terminal element (105) and the electrical conductors (102) connected to it are surrounded by an annular electrical shielding element (110), which encloses the entirety of the electrical conductors (102) at least in the transition area. The electrical shielding elements (110) are wetted with a curable liquid, or at least partially embedded therein, at least in the transition area, so that the electrical shielding element (110) forms a dimensionally stable module after the curable liquid has hardened.