Cable Shield Reconnection via Compression and Conductive Tape
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Solution Overview
Problem
Existing methods for reconnecting shields on electrical connectors are complex, require expert handling, and are not industrializable, leading to prolonged wiring times and potential damage to insulating materials, especially when dealing with multiple cables in aerospace and aeronautical applications.
Innovation Solution
A method involving grouping shielded and unshielded cables into sets, wrapping them with electrically conductive tape to form a local outer shield sheath, and positioning an external conductive strip to create an electromagnetic shield, which can be easily connected to a connector without stripping or damaging the shielding, allowing for efficient re-shielding without expert intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering method is used to connect shielding, then electromagnetic shielding is achieved, but the process becomes complex and requires expert control
Solution Approach 1:
The patent replaces the manual soldering process (mechanical/electrical operation requiring expert skill) with a mechanical compression system. A compression element is inserted into a cavity and compressed axially to simultaneously compress all cable shields against a conductive plate, achieving electrical connection without soldering. This substitution eliminates the need for expert control while maintaining shielding effectiveness.
Solution Approach 2:
The patent merges multiple individual shielding connections into a single integrated operation. Instead of connecting each cable shield separately through soldering, the compression element simultaneously compresses all cable shields against the conductive plate in one action, simplifying the overall process while achieving the same electromagnetic shielding function.
2Reliability
If manual soldering is used for shield connection, then electrical connection is achieved, but wiring time increases significantly
Solution Approach 1:
The patent combines multiple individual shield connections into a single simultaneous operation. The compression element contacts all cable shields at once, establishing electrical connections for all cables in one compression action rather than requiring separate soldering operations for each cable, thereby dramatically increasing wiring speed.
Solution Approach 2:
The patent replaces the time-consuming manual soldering process with a rapid mechanical compression operation. The compression element can be inserted and compressed quickly to establish all shield connections simultaneously, eliminating the prolonged wiring time required for individual soldering while maintaining reliable electrical connections.
3Ease of manufacture
If outer gilding layer is removed from connector, then shield connection is enabled, but insulating block is at risk of damage
Solution Approach 1:
The patent introduces a conductive plate as an intermediary element between the cable shields and the connector body. The compression element compresses the shields against this plate, which is positioned within the connector cavity without requiring removal of the outer gilding layer or insulating block, thus enabling shield connection while protecting the insulating structure.
Solution Approach 2:
The patent segments the shielding connection function into separate components: the conductive plate provides the electrical connection surface, while the compression element provides the compressive force. This segmentation allows the connection to be made through the existing connector structure without damaging the insulating block, as each component performs its specific function independently.
4Reliability
If individual cable shielding is removed and folded, then shield connection is achieved, but the operation becomes complex and delicate
Solution Approach 1:
The patent extracts the cable shields from their individual cable coverings and collects them as a group within the connector cavity. The compression element then compresses all extracted shields simultaneously against the conductive plate, eliminating the need for delicate manual folding and distribution operations while achieving effective shield connection.
Solution Approach 2:
The patent merges the individual shield manipulation operations into a single collective compression action. Instead of separately folding and connecting each shield, all shields are compressed together by the compression element in one operation, greatly simplifying the ease of operation while maintaining connection effectiveness.
5Reliability
If multiple retaining clips are used to hold shields, then shield positioning is achieved, but insulating sheaths are degraded and faults occur
Solution Approach 1:
The patent uses a conductive plate as an intermediary between the shields and the connector structure. The plate provides a stable positioning surface for the shields without requiring direct contact with the insulating sheaths, eliminating the mechanical stress and degradation caused by retaining clips while maintaining shield positioning stability.
Solution Approach 2:
The patent replaces the retaining clip mechanical system with a compression-based system. The compression element applies axial force to position and secure the shields against the conductive plate, eliminating the need for multiple retaining clips that mechanically stress and degrade the insulating sheaths, thus preventing faults.
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
This method simplifies the re-shielding process, reduces time, and ensures optimal grounding of shields, preventing damage to insulating materials while maintaining effective electromagnetic shielding, making it suitable for industrial use in the space and aeronautical fields.
Implementation Method 1
positioning an external conductive strip to create an electromagnetic shield
Implementation Method 2
ensures optimal grounding of shields
Data Source
Figure 1~4a
Figure 4b~5c
Figure 5d~6b
AI summary
The method involves removing only an external insulating sheath of a shielded cable over an annular part located at an end connected to an electrical connector (20) without stripping the cables of electromagnetic shield. The shielded cables are grouped together to form a strand (16). The strand is surrounded by an electrically conductive strip (32) in contact with the electromagnetic shield of the shielded cables, and the electrically conducting strip is connected to the connector. An independent claim is also included for a connection assembly for connecting a strand.