Cable Shield Eversion for Compact Connector Stability

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Solution Overview

Problem

Existing methods for processing cable ends, particularly shielded cables, often result in incomplete stripping of the shielding, leading to exposed wires that can cause short circuits and mechanical instability, and require longer cable connection elements to ensure secure connections.

Innovation Solution

A method involving turning the shielding inside out, protecting the front portion, and brushing the rear portion in a circumferential direction to unbraided wires, which are then wrapped around the cable, allowing for a shorter cable connection element with improved mechanical stability and reduced risk of short circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the shielding is completely cut away to expose the inner part of the cable, then the cable can be connected to the connector unit, but the cable connection element becomes longer and mechanical stability is reduced

Engineering Contradiction:

Improvecable connectionVSAvoidcable connection element length

Core Design Contradiction:

Ease of operationVSLength of moving object

Solution Approach 1:

The shielding is turned inside out (everted) instead of being completely removed. This inversion allows the cable inner part to be exposed for connection while the everted shielding remains attached to provide mechanical support and strain relief, eliminating the need for longer cable connection elements.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

Different portions of the shielding are treated differently: the front portion (closer to the cable end) is protected and remains intact for mechanical connection, while the rear portion is brushed to unbraid wires for electrical connection. This localized differentiation optimizes both mechanical stability and electrical connectivity.

Inventive Principle:

Principle #3Local quality

2Reliability

If the shielding is not completely cut away to maintain mechanical stability, then strain relief is achieved, but exposed wires can cause short circuits

Engineering Contradiction:

Improvemechanical stabilityVSAvoidshort circuit risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The shielding is divided into two zones with different treatments: the front portion is protected to maintain mechanical integrity and strain relief, while the rear portion is brushed to unbraid and contain the wires, preventing them from protruding and causing short circuits.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The brushing operation is performed in advance to unbraid the wires in the rear portion of the everted shielding before final assembly. This preliminary action ensures wires are contained and cannot protrude beyond the cable connection element, preventing short circuits while maintaining mechanical stability.

Inventive Principle:

Principle #10Preliminary action

3Length of moving object

If the cable connection element is made shorter to improve compactness, then space is saved, but the risk of wire protrusion and short circuits increases

Engineering Contradiction:

Improvecable connection element lengthVSAvoidwire protrusion risk

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

The brushing operation is performed in advance to unbraid and contain the wires in the rear portion of the everted shielding. This preliminary wire containment allows the use of shorter cable connection elements without risking wire protrusion, as the wires are already secured in a compact configuration.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By inverting the shielding, the wire-containing portion is positioned inside the everted structure rather than outside. This inversion naturally contains the wires within a compact volume, enabling shorter cable connection elements while preventing wire protrusion.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentEP3952035B1Method and device for machining a cable end as well as correspondingly machined cable

Publication Date: 2022.09.14 MD ELEKTRONIK GMBH

Figure 1
Figure 2(a)~2(g)
Figure 3(a)~3(c)

AI summary

A method and a device (65) for processing one end (3) of a cable (1) and a correspondingly processed cable (1) are described. The cable (1) has a shield (11) made of a wire braid (13) surrounding an inner cable part (5). The method comprises the following steps: turning over an end region (17) of the shielding (11), protecting a front part (19) of the turned-over end region (17) of the shielding (11) closer to the end (3) of the cable (1) against mechanical contact from radially outside, for example by means of a temporarily slipped-on sleeve, while a rear part (21) of the turned-over end region (17) of the shielding (11) further away from the end (3) of the cable (1) remains unprotected and exposed, and brushing the rear part (21) of the turned-over end region (17) of the shielding (11) in a circumferential direction (25) tangential to a circumference of the cable (1).