Clinched Ferrule Shield Connection for High-Voltage Cable Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors for high voltage cables suffer from poor connections between the ferrule and the electrical shield, leading to potential breakage, loosening, and instability due to vibrations, and require costly and time-consuming welding processes.
Innovation Solution
The use of a ferrule with clinched arms that pinch or clinch annular portions, allowing for a secure and robust connection by reducing stress during crimping, and enabling easy assembly and scalability across different cable sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to fix two wound portions of the ferrule, then the connection strength is improved, but the manufacturing cost and time increase
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical crimping system. The ferrule is crimped onto the cable shield using a press or tool, creating a secure mechanical connection without requiring welding operations. This substitution eliminates the time-consuming welding process while maintaining connection integrity through proper mechanical deformation of the ferrule material.
Solution Approach 2:
The ferrule is designed with two separate wound portions that are crimped independently onto the cable shield. This segmentation allows each portion to be secured separately through crimping, distributing the mechanical stress and enabling a more efficient manufacturing process compared to welding the entire ferrule structure as a single unit.
2Strength
If welding is used to fix two wound portions of the ferrule, then the connection strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent replaces the welding process (thermal/chemical system) with a mechanical crimping system. The ferrule is crimped onto the cable shield using a press or tool, creating a secure mechanical connection without requiring welding operations. This substitution eliminates the time-consuming welding process while maintaining connection integrity through proper mechanical deformation of the ferrule material.
Solution Approach 2:
The ferrule design allows the material itself to provide the connection strength through its inherent properties. The crimping process deforms the ferrule material to create a friction-fit and mechanical interlock with the cable shield, utilizing the material's elasticity and strength rather than requiring external welding processes. This self-service approach simplifies manufacturing by eliminating complex welding equipment and procedures.
3Ease of operation
If a clip is used to assemble the outer portion of the electrical shield with an accessory cable, then the assembly is simplified, but the connection stability deteriorates
Solution Approach 1:
The patent merges the ferrule structure with the cable shield assembly, creating an integrated component that performs multiple functions. The ferrule is crimped directly onto the cable shield, combining the functions of mechanical attachment and electrical connection in a single robust structure. This integration eliminates the need for separate clips or additional assembly steps, providing both simplicity and stability simultaneously.
Solution Approach 2:
The ferrule is designed with a curved or annular geometry that matches the cylindrical shape of the cable shield. This curved structure allows the ferrule to conform to the cable shield surface, creating a larger contact area and more stable mechanical interlock when crimped. The curvature enables the ferrule to wrap around and secure the cable shield effectively, providing reliable connection stability while maintaining ease of assembly.
Data Source
AI summary
An electrical connector includes a ferrule configured to receive a portion of a first conductive wire of a high voltage electrical cable. The ferrule is configured to fasten to a cable shield which electrically shields the first conductive wire and to electrically connect the cable shield with a second conductive wire of the high voltage electrical cable. The ferrule has two annular portions. One of the two annular portions has a clinched arm arranged to pinch or clinch the other of the two annular portions. The ferrule is aligned such that the first conductive wire extends through the ferrule in the longitudinal direction and the clinched arm has a free end folded along the longitudinal direction. The electrical connector further includes a crimp portion configured to be connected to the ferrule and crimped to the second conductive wire.