Integrally Formed Cable Stud Assembly for Sealing and Strain Relief
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Solution Overview
Problem
Conventional cable stud assemblies for discrete wire and coaxial cables are cumbersome and expensive due to the requirement of four custom components, leading to a time-consuming assembly process.
Innovation Solution
A cable stud assembly comprising an integrally formed cable stud with a heat deformable tube and a crimp ring, along with a gasket, which reduces the number of custom parts and simplifies the assembly process by using commercial off-the-shelf components and adhesive materials for environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If four custom components (crimp ring, cable stud, braid adaptor, sealing guard) are used to assemble a cable stud assembly, then the assembly provides adequate mechanical and environmental sealing, but the manufacturing cost increases and assembly time is extended
Solution Approach 1:
The patent combines multiple custom components into a single integrated cable stud assembly. The cable stud includes an integrally formed body with a sealed cavity that houses the sealing guard, eliminating the need for separate crimp ring, cable stud, braid adaptor, and sealing guard components. This merging reduces component count while maintaining mechanical strength and environmental sealing through the integrated sealed cavity design.
Solution Approach 2:
The cable stud assembly is designed as a multi-functional component that performs multiple functions: mechanical attachment to the bulkhead, cable support, environmental sealing, and strain relief. The integrally formed body with sealed cavity provides both structural support and sealing, while the aperture accommodates various cable types, making the assembly universal and reducing the need for multiple specialized components.
2Reliability
If four custom components are required for cable stud assembly, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The patent merges four separate custom components into a single integrated cable stud assembly, reducing manufacturing complexity and cost. The integrally formed body is manufactured as one piece with the sealed cavity, eliminating the need for multiple custom part productions, inventories, and assembly operations, thereby reducing overall manufacturing cost while maintaining attachment and sealing functions.
Solution Approach 2:
The cable stud assembly is designed as a cost-effective single-use component that eliminates the need for expensive custom-machined parts. The integrally formed design allows for more economical manufacturing methods compared to assembling four precision-custom components, reducing material and labor costs while providing reliable cable attachment and sealing.
3Strength
If a conventional cable stud assembly process is used, then proper cable securing is achieved, but assembly time is excessive
Solution Approach 1:
The cable stud assembly is pre-configured with the integrally formed body and sealed cavity before installation. The sealing guard is pre-positioned within the sealed cavity, and the aperture is pre-formed to accommodate the cable. This preliminary preparation eliminates the need for time-consuming on-site assembly steps, allowing installers to simply insert and secure the cable, thereby reducing assembly time while maintaining pull-out resistance.
Solution Approach 2:
The patent combines multiple assembly steps into a single integrated component installation. Instead of separately assembling crimp rings, cable studs, braid adaptors, and sealing guards, the integrally formed cable stud assembly requires only one installation operation, significantly reducing assembly time while maintaining the mechanical strength and pull-out resistance through the unified structural design.
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 results in a more cost-effective and efficient assembly process with improved pull-out resistance and leak resistance, reducing manufacturing costs and assembly time while maintaining effective environmental sealing.
Implementation Method 1
a heat deformable tube and/or gasket. The heat deformable tube can include an inner surface having a layer of adhesive disposed thereon
Data Source
AI summary
Cable assemblies comprising a cable (102), an integrally formed cable stud (IFCS) disposed around the cable, a securing member (502, 1100), and a crimp ring (508). The IFCS (108) includes tubular bodies (530, 532, 534) of different sizes horizontally aligned along a common central axis (550) and a flange (536). The flange is disposed between a first and a second one of the tubular bodies and extends outwardly therefrom. The securing member (e.g., a heat deformable tube) is disposed around a first portion of the cable having an exterior insulation material disposed thereon and the first tubular body so as to form a seal therebetween. The crimp ring is formed of a deformable material electrically and mechanically coupling a shielding material of the cable to a third one of the tubular bodies.