Connector Shell Extension for Controlled Wire Bending Radius
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Solution Overview
Problem
Electrical cable assemblies face challenges in managing electromagnetic interference (EMI), fitting into small spaces, and providing effective shielding while maintaining signal transmission and power delivery across multiple components.
Innovation Solution
The cable assembly incorporates wire assemblies with EMI-reducing sleeves and connectors featuring an insulator and conductive layers for shielding, along with extensions that allow controlled bending to manage wire radius and fit within tight spaces, ensuring EMI protection and reliable connectivity across multiple components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If EMI shielding materials and multiple protective layers are added to the cable assembly, then EMI protection is improved, but the cable assembly size and complexity increase
Solution Approach 1:
The cable assembly implements nested shielding structures where an inner conductive layer is positioned within a outer conductive layer, both surrounded by insulating layers. This nested configuration provides enhanced EMI protection through multiple shielding barriers while maintaining a compact overall structure, as each shielding layer is contained within the previous one rather than adding external bulk.
Solution Approach 2:
The cable assembly utilizes composite construction combining multiple materials with different properties: conductive materials (copper braids, conductive polymers) for EMI shielding, insulating materials (polymer layers, ceramic coatings) for electrical isolation, and flexible materials for structural integrity. This composite approach achieves superior EMI protection without requiring a single bulky material, thereby reducing overall complexity.
2Volume of moving object
If the cable assembly is designed to fit in small spaces with controlled bending radius, then space utilization is improved, but the wire routing complexity increases
Solution Approach 1:
The cable assembly incorporates pre-formed bends and curved routing paths designed with controlled minimum radii. The wire harness features smooth curved transitions rather than sharp angles, allowing the assembly to navigate tight spaces while distributing mechanical stress evenly. This predetermined curvature geometry enables compact packaging without requiring complex real-time routing adjustments.
Solution Approach 2:
The cable assembly is divided into modular segments or bundles, with wire groups organized into separate harness sections that can be independently routed. This segmentation allows each segment to be managed separately with its own bending controls, simplifying the overall routing complexity while achieving compact overall dimensions through systematic organization of smaller units.
3Adaptability or versatility
If multiple wire assemblies are connected to a single connector, then connectivity versatility is improved, but the connector complexity and EMI shielding difficulty increase
Solution Approach 1:
The connector is designed as a multi-functional universal interface that accommodates multiple wire assemblies simultaneously. It integrates signal transmission, power delivery, and EMI shielding functions within a single connector body. The connector features multiple contact points and integrated shielding structures that work across all connected wire assemblies, providing versatile connectivity without requiring separate specialized connectors for each function.
Solution Approach 2:
The connector combines multiple shielding functions into a unified structure, where a single conductive shield layer provides EMI protection for all wire assemblies connected to the connector. The insulating body of the connector serves dual purposes: electrical isolation between contacts and structural support for the shielding layer. This merging approach reduces connector complexity compared to having separate shielding components for each wire 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
The solution effectively reduces EMI leakage, manages wire routing, and maintains signal integrity by using shielding braid sleeves and conductive layers to establish ground paths, enhancing the cable assembly's ability to connect and disconnect from various electrical components while meeting size and environmental requirements.
Implementation Method 1
The first sleeve may be made of a material which reduces or eliminates electromagnetic interference (EMI)
Implementation Method 2
The second layer may provide EMI shielding for the rear opening of the shell. The second layer may contact the first sleeve. The second layer may establish a ground path from the first sleeve to the shell
Implementation Method 3
The insulator holds the contacts and prevents the contacts from contacting each other
Data Source
AI summary
The cable assembly includes a first wire assembly. The first wire assembly is connected to a first connector and a second connector. The first connector includes a shell and the shell includes an extension. The extension extends away from the rear of the connector. In one embodiment, the extension is integral with the shell. The extension includes one or more openings. The first wire assembly is bent in a controlled manner at first bend. The first opening in the extension maintains the first wire assembly in the bent position to maintain control of the radius in first bend. The radius is controlled to allow the first wire assembly to fit in a small space.