Electrical Harness Integrated Backshell Shielding
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Solution Overview
Problem
Conventional electrical harnesses are bulky, heavy, and prone to failure due to separate backshells, which contribute to weight and vulnerability to vibrations and temperature changes in applications like gas turbine engines and aircraft landing gear.
Innovation Solution
The use of a braided shield with an integrated backshell and overbraid, eliminating the need for separate backshells, provides enhanced protection against electromagnetic interference, vibration, and tensile stresses, while reducing weight and improving reliability through direct connection of the braided shield to the electrical connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate backshells are used to protect the harness and aid manipulation, then the harness position is preserved and manipulation is aided, but the weight increases and failure risk increases due to vibrations and temperature changes
Solution Approach 1:
The patent integrates the backshell function directly into the electrical connector housing, eliminating separate backshell components. The connector housing itself is designed with reinforced structures that provide the protective functions previously requiring separate backshells, thereby reducing weight and eliminating failure points associated with separate backshell connections.
2Reliability
If many insulated wires and cables are used to create the harness, then the electrical connection requirements are met, but the harness becomes bulky and heavy
Solution Approach 1:
The patent employs a compact connector housing design with integrated shielding and protective features that reduce the overall volume required for harness components. The integrated backshell functions are built into the connector structure, allowing for more space-efficient wiring arrangements while maintaining protection and electrical reliability.
3Strength
If separate backshells are used to protect the harness, then mechanical protection is provided, but the harness becomes more complex and prone to failure at connection points
Solution Approach 1:
The protective backshell functions are merged into the electrical connector housing itself. The connector housing is designed with integrated reinforcement structures, strain relief features, and protective elements that previously required separate backshell components, thereby simplifying the overall structure while maintaining mechanical strength.
4Ease of operation
If conventional harness construction with separate components is used, then assembly flexibility is maintained, but the harness is bulky and heavy
Solution Approach 1:
The integration of backshell functions into the connector housing maintains assembly flexibility while eliminating the weight of separate backshell components. The unified structure allows for straightforward installation and manipulation without the additional weight burden of multiple separate protective elements.
Data Source
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AI summary
Electrical harnesses (100; 140; 400) and methods of manufacturing electrical harnesses (100; 140; 400) are disclosed. The electrical harnesses (100; 140; 400) may comprise an electrically conductive wire (112), an electrical connector (300; 350; 502) in electrical communication with the conductive wire (112), a metal clad fiber ("MCF") braided shield (108) surrounding a portion of the electrically conductive wire (112), and an overbraid (106) surrounding a portion of the MCF braided shield (108), wherein the electrical connector (300; 350; 502) comprises an integrated backshell (310; 356). Methods of making electrical harnesses (100; 140; 400) may comprise connecting an electrical connector (300; 350; 502) with a conductive wire (112), disposing a metal clad fiber ("MCF") braided shield (108) to at least partially surround the conductive wire (112); and disposing an overbraid (106) to at least partially surround the MCF braided shield (108), wherein the electrical connector (300; 350; 502) comprises an integrated backshell (310; 356).