Shielding Braid Termination Using Compressed Spring Element
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Solution Overview
Problem
Existing shielded electrical cable termination methods are not robust enough to withstand automotive vibrations and temperature changes, and often result in high electrical resistance, with soldering making the assembly difficult and expensive.
Innovation Solution
A shielding termination structure using an electrically conductive shield body with a compressed spring element, such as a wave spring washer, to establish a low-resistance connection between the cable shielding and a conductive interface, which absorbs assembly tolerances and maintains high pressure contact under varying conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering is used to attach the braid to the shield, then electrical connection is established, but the assembly becomes much more difficult and expensive
Solution Approach 1:
The patent introduces a crimp ring as an intermediary component between the braid and the shield. The crimp ring is crimped onto the braid to secure it, and then radially expanding resilient elements are used to establish the connection between the crimp ring and the housing shield, eliminating the need for direct welding or soldering.
Solution Approach 2:
The patent replaces the thermal joining process (welding/soldering) with a mechanical joining system consisting of a crimp ring and radially expanding resilient elements. This mechanical system achieves reliable electrical connection without the complexity and cost of thermal processes.
2Ease of manufacture
If a crimp ring with radially expanding resilient elements is used to connect the braid to the housing, then the connection can be established, but it is not sufficiently robust to withstand vibrations and temperature changes
Solution Approach 1:
The patent employs radially expanding resilient elements that provide dynamic adaptation to vibrations and temperature changes. These elements can expand and contract radially to maintain constant contact pressure and electrical connection despite environmental variations, making the connection robust against vibrations and thermal expansion.
3Ease of manufacture
If the braid is crimped directly to the connector housing, then assembly is simplified, but the electrical resistance is too high
Solution Approach 1:
The patent applies local quality by using a shield body with a specific connection region designed for optimal electrical contact. The shield body provides a localized low-resistance path between the braid and the housing, ensuring low electrical resistance at the critical connection point while maintaining overall assembly simplicity.
4Ease of manufacture
If a second ring is press fit over the braid to capture it between two rings, then the braid is secured, but the connection is not robust enough for automotive conditions
Solution Approach 1:
The patent replaces the static two-ring press-fit structure with dynamic radially expanding resilient elements. These elements can actively respond to vibrations and temperature changes by expanding and contracting, maintaining reliable electrical connection under automotive conditions where static structures fail.
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 provides a low-bulk resistance, secure, and easy-to-assemble connection that maintains contact integrity under vibrations, thermal expansion, and cable strain, reducing manufacturing costs and avoiding galvanic corrosion.
Implementation Method 1
an electrically conductive spring element is arranged between said shield body and the interface for establishing the electrical contact in a compressed state of the spring element
Implementation Method 2
the spring element will absorb assembly tolerances thereby eliminating the need for tight manufacturing tolerances
Implementation Method 3
the spring element will ensure high pressure contact that is maintained even under conditions of vibration, differential movement due to thermal expansion or loads due to applied cable strain
Data Source
AI summary
The present invention relates to shielded electrical cables and shielded electrical connectors to be affixed thereto, and in particular to the termination of the shielding braid provided at the electrical cable. According to the present invention, a shielding termination structure for engaging a shielding (104) of a shielded cable (100) having an insulated conductor (102) that is encompassed by said shielding is provided, said shielding termination structure (110) comprising: an electrically conductive shield body (114) for establishing an electrical connection between said shielding (104) and an electrically conductive interface (118), fixing means (126) for securing said shield body (114) at the interface (118); an electrically conductive spring element (120) that is arranged between said shield body (114) and the interface (118) for establishing the electric contact in a compressed state of the spring element (120).