One-Piece Crimp Connector Blank for Shielded Cable Assembly
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Solution Overview
Problem
Existing connectors for shielded cables, particularly in hybrid and electric vehicles, require complex and error-prone multi-step assembly processes, making them difficult to automate and prone to mistakes, especially when joining power connectors to large cross-section cables.
Innovation Solution
A one-piece metal blank with crimping portions for both the electrical component and cable, allowing for a single-step crimping process that minimizes assembly steps and integrates a sealing function, enabling easier automation and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple successive assembly steps are used to join connector components to cable, then each component can be properly assembled, but the assembly process becomes complex and error-prone
Solution Approach 1:
The patent combines multiple separate assembly steps into a single integrated crimping operation. The one-piece blank is designed with multiple crimping portions that can simultaneously or sequentially crimp different components (central contact, shielding braid, outer sheath) in one operation, eliminating the need for multiple separate assembly steps and reducing complexity while maintaining reliability
Solution Approach 2:
The one-piece blank is segmented into multiple functional crimping portions, each designed to engage with different cable components. This segmentation allows each portion to be optimized for its specific crimping function while being part of a single integrated component, resolving the contradiction by enabling complex functionality without increasing assembly process complexity
2Reliability
If multiple components are assembled in successive steps, then proper assembly is achieved, but the assembly time increases
Solution Approach 1:
Multiple crimping operations are merged into a single integrated process. The one-piece blank enables simultaneous or sequential crimping of multiple components in one operation, dramatically reducing assembly time while maintaining the quality requirements through proper design of each crimping portion
Solution Approach 2:
The one-piece blank is pre-configured with all necessary crimping portions and geometries before assembly. This preliminary preparation allows the assembly process to proceed rapidly without requiring intermediate adjustments or setups, improving productivity while ensuring assembly quality through pre-engineered crimping features
3Manufacturing precision
If separate crimping portions are used for different materials, then optimal crimping for each material is achieved, but the number of parts increases
Solution Approach 1:
Multiple separate crimping portions are merged into a single one-piece blank. Each portion within the blank is designed with specific geometry and material properties optimized for its target component (central contact, shielding braid, outer sheath), achieving crimping precision without increasing the number of parts
Solution Approach 2:
Different portions of the one-piece blank have locally optimized properties (geometry, material composition, thickness) tailored to the specific requirements of each cable component being crimped. This local quality optimization enables precise crimping for each material type while maintaining a single integrated part structure
Data Source
AI summary
A first alternative of the application first defines a one-piece metal blank that will make it possible to produce a connector sub-assembly ready to be directly crimped to an insulated and shielded cable, prepared beforehand. A second alternative of the application first defines a pre-assembled connector sub-assembly that incorporates front and rear crimping portions with different electrical and/or mechanical characteristics, and which is ready to be directly crimped to an insulated and shielded cable, prepared beforehand. Either of the two alternatives makes it possible to minimize assembly steps and associated risks such as those due to the processes of fitting together a great many components according to the prior art.