Cable Terminal Device with Integrated Shield Sleeve
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Solution Overview
Problem
Existing terminal devices for transmitting electrical drive power in motor vehicles are complex and expensive to produce and assemble, requiring high plug-in forces and significant structural space, which are not suitable for mass production and long-term reliability.
Innovation Solution
A terminal device with an insulating housing surrounding the cable end, featuring an inner conductive shield sleeve and fastening means for secure connection to a terminal receptacle, along with an outer shield sleeve for improved contact stability and sealing, allowing for low-force assembly and reduced structural space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional terminal devices are used for transmitting electrical drive power, then reliable power transmission is achieved, but the device complexity and production cost increase significantly
Solution Approach 1:
The patent combines the housing and the contact zone of the inner shield sleeve into a single integrated component. The housing comprises an integrated contact zone that directly contacts the shield housing of the terminal receptacle, eliminating the need for separate fastening means and reducing structural complexity while maintaining reliable electrical connection and shielding continuity.
2Power
If conventional terminal devices with large contact sizes are used, then high current transmission is achieved, but the plug-in forces become excessively high
Solution Approach 1:
The patent employs a pressing mechanism that applies preliminary axial force to press the integrated contact zone of the housing against the shield housing of the terminal receptacle before final connection. This preliminary action ensures stable electrical contact and reduces the peak plug-in forces by distributing the contact pressure over the assembly process, enabling high power transmission with lower assembly forces.
3Power
If conventional terminal devices are used, then power transmission functionality is achieved, but the required structural space becomes very large
Solution Approach 1:
The patent implements a nested structure where the inner shield sleeve is positioned within the housing, and the cable is positioned within the inner shield sleeve. This nested arrangement allows the terminal device to maintain effective shielding and power transmission functionality while minimizing the overall structural space and volume required for the connector assembly.
4Ease of operation
If conventional terminal devices are used, then connection functionality is achieved, but the assembly process becomes complex and expensive
Solution Approach 1:
The patent merges the housing and contact zone into a single integrated component that can be manufactured as one piece. This integration simplifies the manufacturing process by reducing the number of parts that need to be assembled, eliminates the need for separate fastening means, and reduces assembly complexity while maintaining reliable electrical connection functionality.
Data Source
AI summary
A terminal device has a housing of insulating material, the housing surrounding a portion of the cable end of a sleeve and having a flange directed towards a terminal receptacle. There is additionally provided an inner shield sleeve of conductive material arranged in the housing and surrounding the cable, the inner shield sleeve is connected conductively to a shield of the cable and which has a flanged contact zone directed towards the terminal receptacle. Fastening screws are used simultaneously to press the housing and the flanged contact zone, resting on the housing, of the inner shield sleeve axially against a shield housing of the terminal receptacle.