Conductive Ferrule Cable Termination Radial Space
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Solution Overview
Problem
Large-diameter signal-carrying cables face challenges in achieving mechanical support and electrical continuity when terminated to connectors due to limited space, as existing solutions struggle to accommodate both mechanical holding and electrical connection effectively.
Innovation Solution
A conductive ferrule with minimal wall thickness is installed over the exposed braided shield of the cable, with small radial ports communicating with internal annular grooves for conductive adhesive injection, forming a strong mechanical and electrical bond. The ferrule is then clamped between conductive connector shells using rivets or screws, ensuring axial and rotational fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional mechanical support mechanism is used to hold the cable bundle, then mechanical support is achieved, but the radial space required exceeds the available space in the connector
Solution Approach 1:
The patent combines mechanical support and electrical continuity functions into a single ferrule component. The ferrule provides both structural support for the cable bundle and a pathway for electrical connection to the shield, eliminating the need for separate mechanical support structures that would consume radial space.
Solution Approach 2:
The ferrule serves multiple functions simultaneously: it provides mechanical support for the cable bundle, maintains structural integrity during termination, and establishes electrical continuity with the conductive shield. This multi-functionality allows the system to achieve both mechanical strength and electrical connection within limited radial space.
2Strength
If the ferrule wall thickness is increased to provide structural strength, then mechanical strength is improved, but the radial space required increases
Solution Approach 1:
The patent employs a conductive adhesive material that bonds the cable assembly to the ferrule interior. This adhesive creates a strong mechanical bond that allows the ferrule to achieve sufficient structural strength with minimal wall thickness, as the bonding material compensates for the reduced ferrule mass.
3Strength
If conductive adhesive is injected through radial ports into annular grooves, then strong mechanical and electrical bond is formed, but the manufacturing process complexity increases
Solution Approach 1:
The ferrule is pre-formed with radial ports and internal annular grooves during manufacturing. These features are prepared in advance to receive the conductive adhesive, allowing the adhesive to be easily injected and distributed along the cable-shield interface. This preliminary preparation simplifies the bonding process compared to creating these features during assembly.
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 allows for efficient mechanical and electrical termination of bundled cables with minimal radial space, providing a secure connection that maintains electrical continuity while accommodating cables of varying diameters.
Implementation Method 1
Conductive adhesive is injected into these ports and flows via the annular grooves, around the cable, then axially forward aft. When cured, the bond forms a strong mechanical attachment and an electrical continuity to the conductive ferrule.
Implementation Method 2
conductive adhesive electrically and mechanically couples the ferrule to the end of the cable
Data Source
AI summary
A cable termination and method are disclosed that electrically and mechanically terminates a bundled cable that requires a radial space only slightly greater than the cable diameter. An electrically-conductive ferrule is connected to an end of a cable, with a conductive adhesive such as a conductive epoxy injected into the ferrule to mechanically connect the ferrule to the cable end, and to electrically couple the ferrule to a shield of the cable, such as a braided wire shield. The ferrule is received by a connector housing, such as being inserted between a pair of connector housing halves, to retain the ferrule mechanically coupled to the housing, and to electrically couple the ferrule to the housing.