Dual Acting Strain Relief for Cable Harnesses
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Solution Overview
Problem
Conventional strain relief mechanisms for electrical cable harnesses are bulky and often cause abrasions between cable shields and conductors, leading to shorts and grounds due to compression clamps.
Innovation Solution
A dual acting strain relief apparatus featuring a main body with a cone member and separate clamps providing independent strain relief for the braided sleeve and electrical wires, ensuring electrical continuity with the chassis while preventing mechanical abrasions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression clamps are used to secure cable shields and conductors, then strain relief is provided, but abrasions in conductor insulation occur leading to shorts and grounds
Solution Approach 1:
The strain relief apparatus is divided into separate functional zones: a first clamp for securing the braided shield and a second clamp for securing the electrical conductors. This segmentation prevents the braided shield from contacting and abrading the conductor insulation while still providing effective strain relief for both components independently.
Solution Approach 2:
A separator or isolation structure is introduced between the braided shield and the electrical conductors. This intermediary element prevents direct contact between the two components, eliminating the harmful abrasion effect while allowing both components to be secured effectively.
2Reliability
If conventional strain relief mechanisms are used, then cable harnesses are secured, but the mechanisms are bulky in size
Solution Approach 1:
Multiple strain relief functions are combined into a single integrated apparatus structure. The base member with its conical protrusion and the multiple clamps work together in one compact unit, providing both braided shield and conductor securing functions without requiring separate bulky mechanisms for each function.
Solution Approach 2:
The apparatus utilizes vertical stacking and three-dimensional arrangement of clamps and securing elements. By arranging components in multiple dimensions rather than spreading them out horizontally, the overall footprint and volume of the strain relief mechanism are reduced while maintaining all necessary securing functions.
3Reliability
If separate clamps are used for braided sleeve and electrical wires, then independent strain relief is provided, but device complexity increases
Solution Approach 1:
The base member serves multiple functions: it provides structural support, contains the conical protrusion for one clamp interface, and provides mounting surfaces for multiple clamps. This multi-functionality reduces the need for additional separate components, maintaining simplicity while achieving independent strain relief for both braided sleeve and electrical wires.
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 prevents conductor shorts and grounds by isolating the braided sleeve from electrical wires and providing a secure, full-surface clamping mechanism that maintains electrical continuity with the chassis, enhancing reliability in cable harness applications.
Implementation Method 1
a tapered cavity therein that penetrates through the secondary clamp and is shaped to receive the cone member. A surface of the tapered cavity and a surface of the cone member form a second set of clamping surfaces
Implementation Method 2
The second set of clamping surfaces provide an electrical path to the chassis
Data Source
AI summary
An apparatus for dual acting strain relief is provided. In one embodiment, a strain relief apparatus comprises: a main body having a base member including a first surface and a second surface, and a cone member extending from the first surface of the base member, the cone member including an orifice that penetrates through the main body to the second surface; a primary clamp that secures to the main body and shaped to interface with the base member to form a first set of clamping surfaces where the orifice penetrates the second surface; and a secondary clamp having a tapered cavity therein that penetrates through the secondary clamp and is shaped to receive the cone member. A surface of the tapered cavity and a surface of the cone member form a second set of clamping surfaces. The second set of clamping surfaces provide an electrical path to the chassis.