Electrical Cable Shielding Strands Connector Assembly
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Solution Overview
Problem
Existing methods for electromagnetic shielding of electrical cables on connectors in the aeronautical industry face issues such as damage to shielding coatings due to mechanical stresses, excessive free length of shielding strands, and the need for multiple connector references to accommodate varying cable diameters, leading to suboptimal shielding performance and increased costs.
Innovation Solution
A method involving stripping the cable shielding, wrapping a conductive stuffing tape around the terminal portion, encircling with a hoop spring blade, and connecting electrically conductive half-shells to the connector, which reduces strand length and constrains shielding without damaging it, allowing for a single connector design to fit various cable diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the free length of shielding strands is increased to accommodate disassembly for maintenance or repair, then the ease of repair is improved, but the electromagnetic shielding performance deteriorates due to transmission faults and crosstalk
Solution Approach 1:
The shielding strands are nested within the cable structure and integrated with the connector housing, eliminating the need for external pigtail extensions. The shielding is incorporated into the connector body itself, allowing maintenance without exposing long vulnerable strands.
Solution Approach 2:
The shielding strands are pre-configured and secured within the connector housing during manufacturing, with sufficient length built-in to accommodate future disassembly and reassembly operations without requiring excessive external length.
2Strength
If mechanical stresses are applied by fastening means on the anvil to secure the connector, then the strength of connection is improved, but the shielding coatings deteriorate due to damage to the fragile strand portion
Solution Approach 1:
The connector is divided into separate functional zones: a reinforcement zone with the anvil and housing that handles mechanical stresses, and a shielding zone that protects the cable shielding. The reinforcement zone absorbs mechanical loads while the shielding zone remains isolated from damaging stresses.
Solution Approach 2:
The connector housing and anvil structure are designed to absorb and distribute mechanical stresses before they can reach the shielding strands. The housing acts as a cushioning element that protects the fragile shielding coatings from crimping and fastening forces.
3Adaptability or versatility
If the diameter of the rear outlet of the connector is adapted to the diameter of the strand, then the adaptability to different cable sizes is improved, but the device complexity increases requiring a large number of different connector references
Solution Approach 1:
The connector housing and anvil are designed with universal dimensions that can accommodate multiple cable and shielding strand diameters. The internal structure provides a standardized interface that works with various cable sizes without requiring different connector references.
Solution Approach 2:
The connector design allows for parameter variations in cable diameter while maintaining the same connector reference. The housing and internal components are designed with tolerances and adjustable features that accommodate different shielding strand diameters within a universal connector type.
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 prevents damage to shielding strands, optimizes their length, and reduces the number of connector references needed, enhancing electromagnetic shielding performance while being cost-effective and easy to maintain or repair.
Implementation Method 1
encircling the said filler strip wound around the end portion of the strand by means of an annular-shaped hoop spring blade
Implementation Method 2
gird the hooping spring leaf between two electrically conductive half-shells comprising complementary coupling means; coupling said half-shells together and connecting them mechanically and electrically to the connector
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to sections of cable ends which are stripped of their individual shield coatings, so that they form single shield plies (2) extending from an end portion of the unstripped strand (1) around which a strip of conductive padding (6) is wrapped until it reaches a predetermined diameter. The plies (2) are rolled up and distributed evenly over the circumference of the end portion of the strand (1), in successive rollings of the padding strip (6). The padding strip (6) is inserted using a ring-shaped reinforcing spring blade (7), all of which is then enclosed between two half-shells which are fastened to each other and connected to the connector.