Integral Crimping Shielding Construction for Wiring Harnesses
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Solution Overview
Problem
The existing shielding construction requires a separate shielding ring for crimping, increasing component complexity, production costs, and reducing working performance due to the need for precise positioning of the ring before crimping.
Innovation Solution
Integrating crimp pieces with the shielding shell, forming them into flat plate-like shapes on the external surface, which simplifies the crimping process and stabilizes the crimped state, allowing for a single-component connection between the shielding member and shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate shielding ring is used for crimping, then the shielding member can be electrically connected to the shielding shell, but the number of components increases and component management becomes complex
Solution Approach 1:
The patent merges the shielding ring function directly into the shielding shell by forming crimp pieces integrally with the shell. The crimp pieces are formed by folding back edge portions of the shell fixing portion or the proximal end portion of the cylindrical shell, eliminating the need for a separate shielding ring component while maintaining electrical connection reliability between the braid and shielding shell.
2Reliability
If a separate shielding ring is used for crimping, then the braid can be inserted and crimped, but the number of production steps increases and working performance deteriorates
Solution Approach 1:
The crimping function is merged into the shielding shell structure itself. The crimp pieces are formed integrally with the shell, allowing the braid to be inserted and crimped directly against the shell structure without requiring separate ring positioning and crimping steps, thereby improving productivity and working performance.
3Reliability
If a separate shielding ring is used, then electrical connection can be achieved, but production costs increase due to additional components
Solution Approach 1:
The shielding shell is designed to include integral crimp pieces formed by folding back portions of the shell itself. This integration eliminates the need for a separate shielding ring component, reducing part count, simplifying component management, and lowering production costs while maintaining reliable electrical connection between the braid and shielding shell.
4Ease of manufacture
If crimp pieces are formed by folding back edge portions, then the shielding shell can be formed by pressing sheet metal, but the crimp pieces require precise formation
Solution Approach 1:
The crimp pieces are pre-formed during the sheet metal pressing process that creates the shielding shell. By incorporating the crimp piece formation into the initial shell forming operation, the precise folding and positioning of crimp pieces is achieved as part of the primary manufacturing process, ensuring manufacturing precision without requiring separate precision forming steps.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A shielding construction is provided which can realize an improvement in working performance and a reduction both in the number of components and production costs. Edge portions 56 are formed on a shell fixing portion 50, disposed in upper and lower positions on the shell fixing portion 50 and formed extending horizontally. Crimp pieces 58 are continuously formed on the edge portions 56, and the crimp pieces 58 are folded back at the edge portions 56 therealong so as to extend towards a distal end 57 of a cylindrical shell portion 49. The crimp pieces 58 each have a rectangular flat plate-like shape and disposed facing oppositely corresponding external flat surface portions 51 of the cylindrical shell portion 49 with a predetermined space defined therebetween. The crimp pieces 58 are formed as a crimping applied portion and the cylindrical shell portion 49 is formed as a crimping bearing portion.