Clinched Ferrule Crimp for Vibration-Stable Shielded Cable Connection
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Solution Overview
Problem
Existing shielded electrical cables for high voltage applications face issues with ferrule breakage during crimping and loose connections due to vibrations, leading to poor electromagnetic compatibility and increased manufacturing costs.
Innovation Solution
The design features a ferrule with two annular portions and a clinched arm that pinches the other portion, allowing for secure crimping and electrical connection of the cable shield with the second conductive wire, reducing stress and preventing breakage by orienting the clinched arm perpendicular to the sheet metal movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a ferrule with protrusion or weld is used to fix two wound portions, then the ferrule can be assembled, but the ferrule breaks or reopens during crimping or under vibration, leading to poor electrical connection
Solution Approach 1:
The ferrule is divided into two separate wound portions that are assembled together and fixed by a clinched arm, rather than attempting to form a complete closed ring. This segmentation allows each portion to be independently crimped onto the cable shield, reducing stress concentration and preventing breakage during assembly and under vibration.
Solution Approach 2:
The clinched arm is oriented perpendicular to the sheet metal movement direction during crimping. This dimensional change in orientation allows the fixing mechanism to engage the two wound portions without creating stress concentrations that would lead to breakage, while maintaining reliable electrical connection under vibration.
2Reliability
If weld is provided on inner side and outer side of ferrule or fully penetrating the ring, then connection integrity may be improved, but manufacturing cost and time increase, and additional inspection is required
Solution Approach 1:
The welding process is completely removed from the ferrule assembly process. Instead of welding the two wound portions together, the patent uses a mechanical clinched arm that engages the portions through friction and geometric interlocking. This extraction of the welding operation eliminates the need for complex welding equipment, multiple welding passes, and post-weld inspection while maintaining connection integrity.
Solution Approach 2:
The clinched arm structure is designed to self-align and self-lock the two wound portions during crimping. The geometry of the clinched arm and the wound portions creates a self-fixing mechanism that does not require external welding or additional fastening operations, simplifying manufacturing while ensuring reliable connection.
3Ease of manufacture
If clip or shrinking tube is used to assemble outer portion of electrical shield with accessory cable, then assembly is possible, but connection loosens under vibration, causing unstable connection resistance and cable loosening
Solution Approach 1:
The ferrule structure merges the functions of shielding connection and cable fixation into a single integrated component. The two wound portions of the ferrule are crimped directly onto the cable shield and accessory cable simultaneously, creating a unified connection that prevents relative movement and maintains stable electrical connection under vibration, eliminating the need for separate clips or shrinking tubes.
Data Source
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AI summary
An electrical connector for a cable having: - a first and second conductive wire, - a cable shield arranged to electrically shield the first conductive wire, wherein the connector has : - a crimp portion (10) configured for crimping the second conductive wire, - a ferrule (20) connected to the crimp portion and configured to receive the first conductive wire, and the ferrule is arranged to fasten the cable shield and electrically connect the cable shield with the second conductive wire, wherein the ferrule has two annular portions (20a, 20b), and one of the two annular portions has at least one clinched arm (20d) arranged to clinch the other of the two annular portions , wherein 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.