Gradient Cable Termination Sleeve for Sunroof Actuator
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Solution Overview
Problem
Cut-to-length riser cables tend to fan out and rattle due to loose individual wires, leading to installation issues.
Innovation Solution
A termination sleeve with a bore shaped to match the pitch helix is attached to the end of the riser cable, fixed using ultrasonic welding or inductive heating for secure fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cut-to-length riser cables are used, then the cable length is precisely controlled, but the individual wires fan out and rattle due to loose ends
Solution Approach 1:
The patent applies preliminary action by pre-forming a loop or eye at the cable end before final installation, and by pre-coating the cable end with adhesive or heat-shrink material. This preliminary preparation prevents wire fanning and rattling during subsequent installation and operation, while maintaining the precise cut-to-length advantage.
Solution Approach 2:
The patent employs nesting by inserting a protective ferrule or sleeve inside the cable end, which contains and organizes the individual wires. This nested structure prevents the wires from fanning out while maintaining the compact, precise length characteristics of cut-to-length cables.
2Ease of manufacture
If traditional cable ending methods are used, then the cable is easy to manufacture, but the cable ends rattle and create installation issues
Solution Approach 1:
The patent introduces an intermediary component such as a ferrule, sleeve, or adhesive coating that mediates between the cable end and the installation environment. This intermediary prevents rattling and improves installation reliability while requiring minimal additional manufacturing steps, thus maintaining ease of manufacture.
Solution Approach 2:
The patent applies parameter changes by modifying the physical state of the cable end through heat treatment, adhesive application, or mechanical compression. These parameter changes stabilize the cable end structure to prevent rattling, while the processes remain integrated into existing manufacturing workflows, preserving manufacturing simplicity.
3Device complexity
If the cable end is left open, then the cable structure is simple, but the loose wires cause fanning and operational instability
Solution Approach 1:
The patent employs flexible shells such as heat-shrink sleeves or polymer coatings that conform to the cable end geometry. These thin-film structures stabilize the wire bundle by providing gentle containment pressure while maintaining cable flexibility and adding minimal structural complexity.
Solution Approach 2:
The patent uses composite materials combining the metal wires with polymer coatings or adhesive matrices at the cable end. This composite structure stabilizes the wire arrangement to prevent fanning, while the materials are selected to maintain compatibility with existing cable construction methods, limiting complexity increases.
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 prevents cable fanning and rattling, ensuring a stable and secure connection, enhancing the cable's operational performance.
Implementation Method 1
the area of the riser cable on which the terminating sleeve is to be fixed is inductively heated before the terminating sleeve is installed
Implementation Method 2
The fixation is performed by heating the entire outer surface of the termination cap by ultrasonic welding
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a method for manufacturing a gradient cable, in particular for actuating sunroofs or cargo area covers of vehicles, in which an end sleeve is attached to a section of the gradient cable, in particular to its second end, to prevent the cable from fraying, characterized by the following method steps: a) manufacturing a gradient cable provided with a gradient helix and manufacturing an end sleeve provided with a bore, wherein a shape corresponding to the second end of the gradient cable is formed within the bore; b) automated joining of the end sleeve to a section, in particular to an end of the gradient cable or automated joining of the gradient cable into the bore of the end sleeve; and c) fixing of the end sleeve to a section, in particular the end of the gradient cable, by heating the gradient cable.