Cable Shield Ferrule Connector for Vibration-Resistant Grounding
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Solution Overview
Problem
Conventional electrical connectors fail to provide effective and robust grounding of shielded cables under high vibration conditions, leading to inadequate EMI protection and reduced service life in high-power applications.
Innovation Solution
A cable shield connector design that interposes the cable shield between inner and outer ferrules, using a canted coil spring for a resilient and robust grounding connection, resistant to vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional sheet metal shielding components are used for EMI protection, then EMI protection is provided, but the connector fails under high vibration conditions
Solution Approach 1:
The patent employs a composite construction combining a metal ferrule (providing structural strength and vibration resistance) with a metal shield (providing EMI protection). The shield is crimped onto the ferrule, creating a composite assembly that leverages the strengths of both materials to simultaneously achieve vibration resistance and EMI protection.
Solution Approach 2:
The ferrule features a curved or spheroidal interface where the shield is crimped onto it. This curved geometry distributes vibration stresses more evenly across the shield-ferrule connection, preventing the sheet metal from failing under high vibration conditions while maintaining effective EMI shielding.
2Reliability
If the cable shield is directly connected to the connector housing, then grounding is provided, but the connection is not robust under high vibration
Solution Approach 1:
The grounding connection is achieved through a composite assembly where the metal shield is crimped onto the metal ferrule, which then contacts the connector housing. This multi-material construction provides both reliable grounding and robust vibration resistance, overcoming the limitations of direct shield-to-housing connections.
Solution Approach 2:
The grounding path is segmented into distinct components: the cable shield, the ferrule, and the connector housing. The shield is crimped onto the ferrule, creating a segmented but mechanically robust grounding connection that can withstand high vibration while maintaining electrical continuity.
3Object-affected harmful factors
If sheet metal shielding components are used, then EMI protection is achieved, but the service life is reduced due to vibration failure
Solution Approach 1:
The composite ferrule-shield assembly combines the EMI protection capabilities of sheet metal with the vibration resistance of a solid ferrule structure. This composite construction eliminates the vibration failure mode of pure sheet metal shields while preserving EMI protection, thereby extending service life in high-vibration applications.
Solution Approach 2:
The curved interface geometry of the ferrule distributes mechanical stresses from vibration across the entire shield-ferrule connection area, preventing localized fatigue failure. This extends the service life of the EMI shielding component while maintaining its protective function throughout the connector's operational life.
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
Provides a reliable and durable electrical connection that maintains EMI protection and power transmission integrity under high vibration conditions.
Implementation Method 1
An inner ferrule includes an inner surface and an outer surface, wherein a portion of the cable shield is disposed along at least a portion of the inner ferrule outer surface. An outer ferrule comprises a first section that is disposed concentrically around the inner ferrule, and wherein the portion of the cable shield is interposed between and in direct contact with each of the inner ferrule and the outer ferrule first section.
Implementation Method 2
an electrically interconnecting element is interposed between the assembly and the housing to provide an electrical connection therebetween. In an example, the interconnecting element is in the form of a canted coil spring extending circumferentially between and contacting opposed surfaces of the assembly and the housing inner cavity.
Data Source
Figure 1A~1B
Figure 1C~2
Figure 3
AI summary
Cable shield grounding electrical connector (100) comprising a cable (16) having a cable shield (18), an inner insulating sleeve (108) disposed radially inwardly from the cable shield, and an inner conductor (112) radially inward of the inner insulating sleeve (108). An inner ferrule (12) includes an outer surface, wherein a portion of the cable shield (18) is disposed along at least a portion of the inner ferrule outer surface. An outer ferrule (14) comprises a first section (32) that is disposed concentrically around the inner ferrule (12), and wherein the portion of the cable shield (18) is interposed between and in direct contact with each of the inner ferrule (12) and the outer ferrule first section (32) thereby forming an assembly (10). The connector (100) comprising a housing (102) having an inner cavity (104) and wherein the assembly (10) is disposed within the inner cavity (104). An electrically interconnecting element (118) is interposed between the assembly (10) and the housing (102) to provide a grounding electrical connection therebetween.