Deformable Ferrule Structure for Cable Retention and Shielding
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Solution Overview
Problem
Open type, crimpable ferrules are weaker in cable retention and have difficulty achieving sufficient electrical shielding due to incomplete closure and exposed cable braiding, which increases the risk of electrical shorting.
Innovation Solution
A ferrule design with a body that is deformed into varying cross-sections to securely fit over a conductive cable, preventing spring-back and ensuring a closed seam for improved retention and shielding, while maintaining cost-effectiveness in manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If open type ferrules are used, then manufacturing efficiency and assembly ease are improved, but cable retention strength and electrical shielding performance deteriorate
Solution Approach 1:
The ferrule body is divided into multiple axial sections (first body portion, second body portion, third body portion) with different cross-sectional configurations. Each section is optimized for specific functions: the first section provides cable retention, the second section maintains seam closure, and the third section ensures electrical shielding. This segmentation allows the open type ferrule to achieve performance previously only available from closed tube ferrules while maintaining manufacturing efficiency.
2Ease of manufacture
If open type ferrules are used, then manufacturing cost is reduced, but electrical shielding performance and cable retention deteriorate
Solution Approach 1:
Different sections of the ferrule body are given different local qualities through varying cross-sectional configurations. The first body portion has a cross-section optimized for cable retention, the second body portion maintains a closed configuration for seam closure, and the third body portion provides complete coverage for electrical shielding. This local differentiation ensures that each section performs its specific function optimally, reducing electrical shorting risk while maintaining cost-effectiveness.
3Strength
If closed tube ferrules are used, then cable retention and electrical shielding are improved, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
The ferrule transitions from a static closed tube design to a dynamic multi-section structure that can be efficiently crimped during assembly. The varying cross-sections are designed to deform in a controlled manner during the crimping process, allowing the ferrule to adapt to the cable and connector components while maintaining strong retention and shielding performance. This dynamic design simplifies assembly compared to traditional closed tube ferrules.
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 ferrule design enhances cable retention and electrical shielding, reducing the risk of electrical shorting while maintaining efficiency in manufacturing and assembly.
Implementation Method 1
a first body portion deformed into a cross-section corresponding to the first portion of the conductive cable, and a second body portion deformed into a cross-section corresponding to the second portion of the conductive cable
Data Source
AI summary
A cable assembly comprises a conductive cable including an exposed conductive first section having a first cross-section, and a second section adjacent the first second and having a second cross-section distinct from the first cross-section. A ferrule is positioned over the conductive cable and includes a body defining a seam formed therethrough in an axial direction. The ferrule defines a first body portion deformed into a cross-section corresponding to the first portion of the conductive cable, and a second body portion deformed into a cross-section corresponding to the second portion of the conductive cable.