Electrical Connector EMC Shielding Braid Assembly
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Solution Overview
Problem
The complexity and variability in plug configurations result in intricate and time-consuming manufacturing processes for electrical connectors, particularly due to the need for precise cutting and processing of EMC shielding braids, leading to potential length tolerances and assembly challenges.
Innovation Solution
A method where the EMC shielding braid is bent over the cable sheath edge and formed into multiple layers outside the sheath, allowing for simplified assembly and processing without cutting, using existing components like clamping sockets and sleeves to define and position the braid layers precisely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the EMC shielding braid is cut to length during manufacturing, then the length can be precisely adjusted, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The EMC shielding braid is pre-formed with an extended portion that protrudes from the cable sheath at the desired length and position before assembly. This preliminary preparation eliminates the need for cutting operations during the manufacturing process, as the braid is already positioned correctly to be bent back and secured by the clamping socket.
Solution Approach 2:
The extended portion of the EMC shielding braid is extracted or separated from the main cable structure by protruding it from the cable sheath. This allows the extended portion to be independently positioned and bent back without affecting the rest of the cable assembly, simplifying the manufacturing process.
2Manufacturing precision
If the EMC shielding braid is bent back and formed into multiple layers, then the positioning precision is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The EMC shielding braid is designed to be self-positioning through its own geometry. The extended portion naturally protrudes from the cable sheath and can be bent back by the clamping socket without requiring additional positioning mechanisms or complex assembly steps. The braid's own structure enables its precise positioning.
Solution Approach 2:
The EMC shielding braid is bent back into a curved or folded configuration outside the cable sheath, forming multiple layers. This curvature allows the braid to be compactly positioned and secured by the clamping socket while maintaining electrical continuity and shielding effectiveness.
3Manufacturing precision
If cutting operations are performed on the EMC shielding braid, then the length can be precisely controlled, but length tolerances and assembly challenges arise
Solution Approach 1:
The desired length of the EMC shielding braid extended from the cable sheath is predetermined and prepared in advance during cable manufacturing. This preliminary action ensures that the braid has the correct length before assembly, eliminating the need for cutting operations that could introduce tolerances or damage the braid structure.
Data Source
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AI summary
The invention relates to a connector (1) with a connector housing (2) in which a terminal socket (11), a terminal sleeve (10) and a shield sleeve (9) of the connector (1) are received, wherein the annular terminal sleeve (10) is arranged circumferentially surrounding a partial region (18) of the annular terminal socket (11) and a first EMC shield braid space (29) for receiving a first shield braid layer (30) is formed radially between an inner side (10b) of the terminal sleeve (10) and an outer side (11a) of the partial region (18) of the terminal socket (11) surrounded by the terminal sleeve (10), and the annular shield sleeve (9) is arranged circumferentially surrounding the terminal sleeve (10), wherein a second EMC shield braid space (31) for receiving a second shield braid layer is formed between an inner side (9b) of the shield sleeve (9) and an outer side (10a) of the terminal sleeve (10). several further layers of shielding braid (32, 33) are formed.