Angled Harness Backshell Overbraid for EMI Shielding
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Solution Overview
Problem
Existing harness assemblies face challenges in minimizing electromagnetic interference (EMI) while balancing considerations such as pull strength, strain relief, repairability, environmental sealing, and weight, particularly in cable designs for connecting sensors like QDM in vehicle engines.
Innovation Solution
A harness assembly design featuring a cable with an integrated backshell at an angle, an external braid, and an overbraid with two layers formed from a single material folded over itself, providing enhanced EMI shielding and reduced weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple separate braids are used to provide EMI shielding, then EMI protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate braid layers into a single integrated braid structure that provides equivalent or superior EMI shielding. This single braid integrates the functionality of what would traditionally require multiple separate braid components, thereby reducing assembly steps and manufacturing complexity while maintaining shielding effectiveness.
Solution Approach 2:
The patent employs a composite braid structure with varying wire densities and material compositions within a single braid. By strategically designing the braid with different wire densities at different locations (higher density near the connector, lower density toward the cable end), it achieves optimized EMI protection across different zones without requiring multiple separate braid components.
2Object-affected harmful factors
If thicker or multiple braid layers are used for EMI shielding, then EMI protection is improved, but weight increases
Solution Approach 1:
The patent applies local quality by varying the wire density and material properties of the braid at different locations along its length. The braid has higher wire density and thicker construction near the connector where EMI protection is most critical, and gradually transitions to lower density toward the cable end. This localized optimization provides maximum EMI shielding where needed while minimizing unnecessary material and weight in less critical areas.
3Object-affected harmful factors
If traditional multi-component braid structures are used, then EMI shielding is provided, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent merges multiple braid components into a single pre-assembled braid unit that can be installed in one step. This integrated braid structure eliminates the need for separate assembly operations for multiple braid layers, reducing manufacturing complexity and assembly time while maintaining comprehensive EMI shielding coverage.
Solution Approach 2:
The patent employs preliminary action by pre-configuring the braid with its varying wire density profile and integrated structure during manufacturing. This pre-engineered design allows the braid to be installed as a complete shielding solution without requiring field assembly or adjustment, thereby simplifying the final installation process and reducing assembly time.
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 design effectively reduces potential gaps in the braid, enhancing EMI shielding, improving strain relief, and minimizing weight and cost, while maintaining environmental protection and ease of assembly.
Implementation Method 1
The overbraid is a single material folded over at least a portion of itself to form the two layers
Implementation Method 2
cable having a cable shielding around at least a portion of a plurality of wires... external braid disposed around at least a portion of the backshell and the cable
Data Source
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AI summary
A harness assembly may include a cable having a cable shielding around at least a portion of a plurality of wires, a connector with an integrated backshell arranged at an angle with respect to the cable, an external braid disposed around at least a portion of the backshell and the cable, and an overbraid around at least a portion of the external braid, the overbraid having two layers.