Conductive Cable Seal Integrating Shielding and Sealing

Solution Overview

Problem

Existing electrical connector assemblies for high voltage systems require additional space for crimped ferrules to connect shielded cables, which is a design concern in compact packaging environments, such as modern vehicles, and existing cable seals do not efficiently provide both sealing and electromagnetic interference shielding.

Innovation Solution

A sealed electrical connector assembly using a resilient, electrically conductive cable seal made of graphite-filled silicone elastomer that provides both sealing and an electrical connection between the cable shield and terminal shield, eliminating the need for separate ferrules by integrating the sealing and shielding functions into a single component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If crimped ferrules are used to connect cable shield to terminal shield, then electrical connection is achieved, but connector assembly size increases and manufacturing complexity increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidconnector assembly size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The cable seal is modified to integrate both sealing and electrical connection functions. The cable seal includes a shield contact portion with conductive material that directly contacts the cable shield, and a housing contact portion that contacts the terminal shield, eliminating the need for separate ferrules and reducing connector assembly size.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable seal serves multiple functions simultaneously: it provides environmental sealing between the cable and housing, and it provides electrical connection between the cable shield and terminal shield. This multi-functionality eliminates the need for separate ferrule components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If crimped ferrules are used to connect cable shield to terminal shield, then electrical connection is achieved, but device complexity increases

Engineering Contradiction:

Improveelectrical connectionVSAvoidconnector assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable seal is modified to integrate both sealing and electrical connection functions. The cable seal includes a shield contact portion with conductive material that directly contacts the cable shield, and a housing contact portion that contacts the terminal shield, eliminating the need for separate ferrules and reducing connector assembly size.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable seal serves multiple functions simultaneously: it provides environmental sealing between the cable and housing, and it provides electrical connection between the cable shield and terminal shield. This multi-functionality eliminates the need for separate ferrule components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional cable seals are used, then sealing is achieved, but electromagnetic interference shielding is not provided

Engineering Contradiction:

ImprovesealingVSAvoidelectromagnetic interference

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The cable seal is made from a composite material containing conductive particles (such as carbon black, metal powders, or metal flakes) dispersed in an elastomeric matrix. This composite structure provides both the flexibility and sealing properties of rubber and the electrical conductivity needed for EMI shielding.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The electrical conductivity of the cable seal is adjusted by modifying the concentration, type, and distribution of conductive particles within the elastomeric material. This allows optimization of both sealing performance and EMI shielding effectiveness.

Inventive Principle:

Principle #35Parameter changes

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

The solution reduces the size of the connector assembly by eliminating the need for ferrules, thereby saving manufacturing costs and space, while maintaining effective sealing and electromagnetic interference shielding within the desired frequency range.

Implementation Method 1

The cable seals are formed of a resilient, electrically conductive material so that the cable seal both provide sealing between the shielded cable and a housing of the electrical connector as well as providing an electrical connection between a cable shield and a terminal shield within the electrical connector

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10205268B1Electrical connector having cable seals providing electromagnetic shielding

Publication Date: 2019.02.12 DELPHI TECHNOLOGIES INC

AI summary

An electrical connector assembly includes a shielded wire cable having an inner core, an inner insulator surrounding the inner core, a cable shield surrounding the inner insulator, and an outer insulator surrounding the cable shield, a terminal attached to the inner core, a terminal shield surrounding the terminal, and a cable seal formed of an electrically conductive resilient material, wherein a first portion of the cable seal is in compressive contact with portions of the cable shield and the terminal shield, thereby providing an electrically conductive path between the cable shield and the terminal shield. The electrical connector assembly further includes a housing in which the terminal is disposed. A second portion of the cable seal is in compressive contact with a portion of the outer insulator and an inner wall of the housing, thereby inhibiting intrusion of contaminants into the housing.