Planar Bus Bar Splicing Device for Shielded Wire Cables
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Solution Overview
Problem
Existing splicing devices for shielded wire cables require a 'fan out' of core conductors, increasing the overall length and complexity, especially in one-to-many splicing configurations like Y-splices or H-splices, which complicates electrical continuity and increases cable length.
Innovation Solution
A wire harness assembly with a planar conductive bus bar for welding core conductors and a conductive sleeve with ferrules or elastomeric bands to connect shield conductors, reducing the overall length by eliminating the need for 'fan out' and providing a robust electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If core conductors are arranged in a traditional splicing configuration, then electrical connection is achieved, but the overall length of the splicing device increases due to required 'fan out'
Solution Approach 1:
The patent applies nesting by placing the conductive bus bar inside the conductive sleeve, which is in turn placed inside the outer insulator. This nested arrangement allows multiple components to occupy overlapping spatial volumes, eliminating the need for conductors to fan out laterally and significantly reducing the overall length of the splicing device while maintaining electrical connectivity.
Solution Approach 2:
The patent transitions from a two-dimensional fan-out layout to a three-dimensional nested configuration. By arranging components along the longitudinal axis rather than spreading them radially, the invention utilizes the third dimension to achieve compact integration, reducing the device length without compromising electrical connection quality.
2Reliability
If shield conductors are cut back to join center conductors, then electrical continuity of center conductors is achieved, but interconnection of shield conductors becomes complicated
Solution Approach 1:
The conductive bus bar serves multiple functions simultaneously: it provides electrical connection for center conductors, maintains shield conductor continuity through the conductive sleeve, and offers mechanical support for the spliced cables. This multi-functionality eliminates the need for separate interconnection mechanisms for shield conductors, simplifying the overall splicing process.
Solution Approach 2:
The conductive sleeve acts as an intermediary component that facilitates shield conductor interconnection without requiring direct manipulation of the shield conductors themselves. By providing a conductive pathway through the sleeve, the invention simplifies shield conductor connection while maintaining electrical continuity.
3Adaptability or versatility
If a one-to-many splicing configuration is used, then cable routing flexibility is improved, but cable length and splicing device length increase
Solution Approach 1:
The nested configuration allows multiple cables to be spliced in a one-to-many arrangement without increasing overall device length. By nesting the bus bar within the sleeve and insulator assembly, the invention accommodates multiple cable connections along the longitudinal axis, providing routing flexibility while maintaining compact dimensions.
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 reduces the overall length of the splicing device by 38% compared to existing methods, simplifies the splicing process, and maintains electrical continuity, making it suitable for high-voltage applications in vehicles.
Implementation Method 1
The first and second exposed core conductors are welded to the bus bar, thereby electrically connecting the first and second exposed core conductors
Implementation Method 2
The conductive sleeve defines a first contact attached to the first ferrule, a second contact attached to the second ferrule, a third contact attached to the third ferrule, and a fourth contact attached to the fourth ferrule, thereby providing a conductive path between the first, second, third, and fourth shield conductors
Implementation Method 3
The first band is attached to the first and third shield conductors and the second band is attached to the second and fourth shield conductors. The first and seconds bands are in contact with the conductive sleeve, thereby providing a conductive path between the first, second, third, and fourth shield conductors
Data Source
AI summary
A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables that are spliced together is presented. The assembly includes a splicing device having a generally planar bus bar formed of a conductive material, wherein the exposed core conductors of the shielded wire cables are welded to the bus bar, thereby electrically interconnecting the exposed core conductors. A conductive sleeve encloses bus bar and interconnects the shield conductors of the shielded wire cables, providing shielding for the exposed core conductors and continuity for the shield conductors. An outer insulator enclosing the conductive sleeve. A method of splicing shielded wire cables using such a device is also presented herein.