Shielded Cable Connector Shield Eversion Prevention
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Solution Overview
Problem
Existing methods for manufacturing shielded cables used in vehicles and aircrafts face challenges in achieving high electromagnetic compatibility (EMC) and efficient transmission of high-frequency signals while requiring simple construction, minimal installation space, and narrow bending radii, especially in the region of connectors.
Innovation Solution
A method involving the exposure of the shield by removing the jacket, attaching a support clamp electrically contacted to the shield, severing the shield to prevent it from being folded over the clamp, and mounting a sleeve radially outwardly to the clamp, ensuring the shield is not everted and maintaining electrical contact without intermediate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the shield is folded over the support clamp, then the cable structure is compact, but the shield may be everted causing EMC problems
Solution Approach 1:
The shield end is severed at a specific length before the folding operation to prevent eversion during the subsequent folding process. This preliminary action ensures that the shield cannot be everted even when folded over the support clamp, maintaining EMC integrity while achieving compact structure.
2Reliability
If the shield is severed to prevent eversion, then EMC imperviousness is improved, but the projecting portion length must be precisely controlled
Solution Approach 1:
A support clamp is introduced as an intermediary component between the shield and the connector. The clamp provides a reference surface for severing the shield at the correct length, ensuring that the projecting portion is precisely controlled without requiring complex measurement systems. The clamp acts as a physical stop that defines the maximum allowable length of the projecting portion.
3Reliability
If a sleeve is mounted radially outwardly of the support clamp, then electrical contact is ensured, but the cable diameter increases
Solution Approach 1:
The sleeve is nested radially outwardly of the support clamp, with the clamp itself nested on the shield. This nested arrangement ensures that the sleeve is positioned correctly to provide electrical contact with the shield through the clamp, while minimizing the overall cable diameter by utilizing the existing radial space rather than adding axial length.
4Volume of moving object
If the shield is severed close to the support clamp, then installation space is reduced, but the risk of shield eversion increases
Solution Approach 1:
The shield is severed at a predetermined length that is specifically calculated to prevent eversion while minimizing projection. The severing operation creates a geometric constraint where the remaining shield portion is too short to be everted over the clamp, even when folded. This preliminary anti-action eliminates the eversion risk before the folding operation occurs.
Data Source
AI summary
A method for manufacturing a cable having a wire, a shield, a jacket, and a sleeve electrically contacted to the shield, includes removing the jacket at an end of the cable so that the shield is exposed. A support clamp is attached in such a way that the support clamp is electrically contacted to the shield and that, at an end of the shield, a projecting portion protrudes axially from the support clamp, the shield surrounded by the support clamp having a radial distance from an outer contour of the support clamp. The end of the shield is severed in such a way that, after the severing operation, a length of the projecting portion is shorter than the radial distance in a state in which the shield is folded radially outwardly. The sleeve is mounted so that it is disposed radially outwardly of the support clamp and electrically contacted thereto.