Cable Junction Shielding Continuity Without Housing
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Solution Overview
Problem
Existing cable junctions for electrical cables in motor vehicles require costly and complex junction housings, occupy excessive space, and suffer from significant electromagnetic leaks due to large openings in the shielding assembly.
Innovation Solution
A cable junction design that eliminates the need for a junction housing by using a flexible common shield with conductive sleeves and clamping devices to ensure shielding continuity between independent shielding braids and a connector shield, minimizing openings and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a junction housing is used to connect shielding braids, then shielding continuity is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the junction housing component entirely, using only the cable jackets themselves to provide the shielding connection. The shielding braids are directly connected through the cable assembly without requiring a separate housing structure, thus achieving shielding continuity while reducing device complexity.
Solution Approach 2:
The cable jacket is given multiple functions: it serves both as the insulating protective covering and as the shielding connection medium. By making the cable jacket itself conductive or by using it to hold the shielding braid in place, the patent eliminates the need for separate shielding housing components.
2Reliability
If a junction housing is used to connect shielding braids, then shielding continuity is achieved, but manufacturing cost increases
Solution Approach 1:
The patent removes the junction housing component from the assembly, eliminating its manufacturing cost. The shielding continuity is achieved through a simpler configuration that uses existing cable components rather than requiring an additional manufactured part.
Solution Approach 2:
The patent merges the functions of the cable jacket and shielding connection into a single integrated structure. By combining these functions, the patent eliminates the need for separate housing components and reduces overall manufacturing complexity and cost.
3Ease of operation
If large openings are provided in shielding assembly, then ease of cable insertion is improved, but electromagnetic leakage increases
Solution Approach 1:
The patent uses flexible cable jackets that can be easily manipulated during assembly. The jackets are designed to be pliable enough to accommodate cable insertion while maintaining their shielding integrity, eliminating the need for large openings that would compromise electromagnetic protection.
4Reliability
If junction housing is used, then shielding connection is achieved, but space requirement increases
Solution Approach 1:
The patent merges the shielding connection function into the cable assembly itself, eliminating the need for a separate junction housing. This integration significantly reduces the space required for the cable connection while maintaining shielding effectiveness.
Solution Approach 2:
The shielding braid is nested within the cable jacket structure, and the connection is made through the cable assembly itself rather than requiring an external housing. This nested configuration minimizes the overall volume occupied by the cable junction.
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 provides a cost-effective, compact, and low-leakage shielded cable junction that maintains electromagnetic integrity without the need for a housing, simplifying manufacturing and reducing space usage.
Implementation Method 1
Each cable 120, 122 comprises its own independent conductive braid shield 128, 130... The cables are conductively connected together by their respective braid shields 128, 130
Implementation Method 2
A cable junction 106 comprises a common flexible shield 148 for surrounding and conductively connecting together the braid shields 128, 130 of the cables 120, 122
Data Source
AI summary
The cable junction includes at least two electrical cables extending side by side, each including its own independent shield and a front end section where its independent shield is stripped off, a common shield surrounding the front end sections and the independent shields of the cables, and a clamping device for clamping the common shield on the independent shields. The clamping device includes internal clamping means for clamping the common shield on flanks of the independent shield sheaths.