EMI Connector Ferrule Segmented Design for Serviceable Sealing
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Solution Overview
Problem
Existing electrical connector ferrules complicate the assembly and disassembly process, are not easily removable during service, and lack effective sealing against fluid ingress, particularly between the protective sleeve and ferrule connections, and are not adaptable to various sleeve configurations without separate components.
Innovation Solution
A ferrule design with a cylindrical wall and radially outwardly extending annular beads and seal members provides a watertight, easy-to-assemble/disassemble connection between a textile sleeve and electrical connector, allowing for a reliable ground path and adaptable to various sleeve configurations with an adjustable clamp ring for secure sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection between the protective sleeve and ferrule is located within the electrical connector, then the connection is protected, but the assembly process becomes complicated and the sleeve cannot be removed during service without removing the ferrule from the electrical connector
Solution Approach 1:
The ferrule is segmented into distinct functional zones: a first end for sleeve attachment, a middle section with sealing features, and a second end with an annular rim for connector attachment. This segmentation allows the ferrule to provide protected connections while maintaining serviceability, as the sleeve can be accessed and removed from the first end without disturbing the connector connection at the second end.
Solution Approach 2:
The ferrule acts as an intermediary component between the protective sleeve and the electrical connector. It provides a transition zone that protects the connection while allowing service access. The ferrule's structure with its sealed cavity and annular rim mediates between the need for protection and the need for serviceability.
2Reliability
If the connection between the protective sleeve and ferrule is located within the electrical connector, then the connection is protected, but fluid ingress resistance is insufficient between connection locations
Solution Approach 1:
A seal member, such as an O-ring or gasket, is positioned within the ferrule's sealed cavity to create a flexible sealing barrier. This seal prevents fluid ingress between the protective sleeve and ferrule connection at the first end, and between the ferrule and electrical connector at the second end, while maintaining the protected connection structure.
Solution Approach 2:
The seal member is pre-installed in the ferrule's sealed cavity to provide beforehand protection against fluid ingress. This preventive sealing measure ensures that fluid cannot penetrate the connection points before any potential failure or exposure occurs.
3Adaptability or versatility
If separate ferrules or protective sleeve configurations are used for individual applications, then adaptability to various sleeve configurations is achieved, but device complexity and cost increase
Solution Approach 1:
The ferrule is designed as a universal component with a standardized structure that can accommodate various protective sleeve configurations. The first end of the ferrule can interface with different sleeve types, and the annular rim at the second end provides a standardized connection interface for the electrical connector. This multi-functional design eliminates the need for separate ferrule configurations for different applications.
4Ease of manufacture
If a simple ferrule design is used, then manufacturing cost is reduced, but sealing effectiveness against fluid ingress is insufficient
Solution Approach 1:
A seal member, such as an O-ring or gasket, is positioned within the ferrule's sealed cavity to create a flexible sealing barrier. This seal prevents fluid ingress between the protective sleeve and ferrule connection at the first end, and between the ferrule and electrical connector at the second end, while maintaining the protected connection structure.
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 enables an economical, reliable, and adaptable connection that is easy to assemble/disassemble, maintains a watertight seal, and allows for easy service access without removing the ferrule from the connector, while providing a secure ground path and improved resistance to fluid ingress.
Implementation Method 1
at least one seal member is disposed in the cavity for sealed abutment with the inner surface and the elongate electrical member
Data Source
Figure 1~1A
Figure 2~3
Figure 4
AI summary
A ferrule configured to couple a textile sleeve to an electrical has a cylindrical wall with an inner surface providing a cavity sized for receipt of an elongate electrical member therethrough. The cylindrical wall extends between a first end configured for attachment within a cavity of the textile sleeve and a second end having a radially outwardly extending annular rim configured for attachment to the electrical connector. The cylindrical wall has at least one radially outwardly extending annular bead adjacent the first end with the annular bead providing a radially inwardly facing annular pocket. At least one seal member is disposed in the cavity for sealed abutment with the inner surface and the elongate electrical member.