Friction Fit Backshell for Shielded Cable Interconnects
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Solution Overview
Problem
Conventional methods for terminating multiple shielded wire bundles to a single circular connector are time-consuming, prone to failure, and occupy large potting volumes, often requiring soldering which can lead to corrosion risks and space inefficiencies.
Innovation Solution
An interconnect system comprising a connector, an adapter ring, and a backshell with threaded and non-threaded coupling portions, allowing mechanical attachment without soldering, and using band clamps to secure shields, reducing the need for soldering and minimizing potting volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to terminate shields to connectors, then reliable electrical connection is achieved, but corrosion risk increases and manufacturing complexity increases
Solution Approach 1:
The patent extracts the harmful soldering process from the shield termination procedure and replaces it with a mechanical friction fit system. The backshell directly contacts the shield through friction between mating surfaces, eliminating the need for solder and flux, thereby removing the source of corrosion risk while maintaining reliable electrical connection.
Solution Approach 2:
The patent replaces the thermal/chemical soldering system with a purely mechanical friction fit system. The backshell and shield are joined through friction between precisely machined mating surfaces, substituting the complex soldering process (heating, flux application, solder deposition) with a simpler mechanical attachment that avoids corrosion-prone materials.
2Reliability
If conventional soldering methods are used for shield termination, then electrical connection is established, but assembly time increases and productivity decreases
Solution Approach 1:
The patent removes the time-consuming soldering steps (flux application, heating, solder feeding, cooling, cleaning) from the assembly process and replaces them with a rapid friction fit attachment. The backshell is simply pressed onto the shield, establishing reliable electrical connection in a single motion, thereby dramatically increasing assembly speed and productivity.
3Adaptability or versatility
If traditional shield termination approaches are used, then multiple wire bundles can be connected, but potting volume increases and space efficiency decreases
Solution Approach 1:
The patent merges multiple shield termination functions into a single integrated backshell structure. The backshell simultaneously accommodates multiple wire bundles, provides friction fit attachment for all shields, and establishes electrical connections for all bundles in one unified component, thereby reducing the overall potting volume required compared to separate termination components for each bundle.
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 system facilitates faster, reliable termination of multiple shielded wire bundles with reduced risk of corrosion and space savings by eliminating the need for soldering and minimizing potting volume, thus enhancing assembly efficiency and space optimization.
Implementation Method 1
The proximal coupling portion of the backshell and the non-threaded distal coupling portion of the adapter ring can be mechanically attached through a friction fit between inner surfaces of the fingers of the proximal coupling portion of the backshell and an outer surface of the non-threaded distal coupling portion of the adapter ring.
Data Source
AI summary
Various technologies described herein pertain to interconnect systems for electrical cables. An interconnect system can include a connector, an adapter ring, and a backshell. The connector includes a threaded distal coupling portion. The adapter ring includes a threaded proximal coupling portion and a non-threaded distal coupling portion. The backshell includes a proximal coupling portion and a port. The threaded proximal coupling portion of the adapter ring and the threaded distal coupling portion of the connector can be mechanically attached. Additionally, the proximal coupling portion of the backshell and the non-threaded distal coupling portion of the adapter ring can be mechanically attached. A wire bundle can enter the backshell through the port, pass through the adapter ring, and terminate at the connector. A shield that encloses the wire bundle can terminate at the backshell such that an end of the shield is positioned around an outer surface of the port.