Electromagnetically Shielded Cable Mold Embedding
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Solution Overview
Problem
Existing electromagnetically shielded cables face issues with inconsistent crimps between the braided metallic shield and the shell, leading to electromagnetic radiation leakage and interference, due to difficulties in evenly spreading and securing the shield, which results in unraveling and galvanic corrosion, affecting the cable's performance and reliability.
Innovation Solution
An electromagnetically shielded cable design where the end portion of the shield is embedded within the shell using a mold, ensuring a strong and consistent connection by inserting the shield into the mold and embedding it with a hardenable material, such as molten metal, to form a cohesive and durable crimp.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a braided metallic shield is crimped to a terminal end using traditional methods, then the shield can be attached to the shell, but the crimp becomes inconsistent and the shield may unravel, creating holes that allow electromagnetic radiation leakage
Solution Approach 1:
The shield end is pre-formed into a tubular configuration before assembly, creating a predetermined structure that receives the terminal end. This preliminary shaping ensures proper alignment and distribution of forces during crimping, preventing inconsistent crimps and shield unraveling that would create electromagnetic radiation leakage holes
Solution Approach 2:
The terminal end is inserted into the pre-formed tubular shield end, creating a nested structure where the terminal is contained within the shield's tubular configuration. This nesting ensures the terminal remains properly positioned during crimping and prevents shield wires from unraveling outward, maintaining shield integrity
2Manufacturing precision
If the shield is held in place during crimping, then consistent contact pressure can be achieved, but it is difficult to hold the shield evenly without causing bunching or minimal contact pressure at certain places
Solution Approach 1:
The shield end is pre-formed into a tubular shape with a predetermined geometry that facilitates proper positioning during assembly. This preliminary configuration ensures the shield sits evenly on the terminal end without requiring complex holding fixtures, eliminating bunching and ensuring uniform contact pressure distribution during crimping
Solution Approach 2:
The shield end is given a specific local tubular geometry at its terminal portion, different from the rest of the braided shield structure. This localized structural modification provides self-alignment and even distribution of contact pressure during crimping, improving manufacturing precision without complicating the overall assembly process
3Ease of manufacture
If the terminal end of the shield is expanded to insert the support, then the support can be installed, but the wires that form the braid separate, creating holes that allow electromagnetic radiation to penetrate
Solution Approach 1:
The shield end is pre-formed into a tubular configuration that is designed to receive and accommodate the terminal end insertion. This preliminary shaping allows the terminal to be inserted without requiring expansion of the shield wires, preventing separation of braid wires and creation of holes that would compromise electromagnetic shielding effectiveness
Solution Approach 2:
The terminal end is nested within the pre-formed tubular shield structure, allowing installation without expanding the shield. The nested configuration maintains wire integrity and prevents gaps or holes in the braid, ensuring continuous electromagnetic shielding while facilitating easy terminal installation
4Ease of manufacture
If traditional crimping methods are used, then the shield can be attached to the shell, but determining the pull strength of the cable becomes difficult
Solution Approach 1:
The shield end is pre-formed into a tubular configuration with a standardized geometry that creates a consistent and repeatable crimp structure. This preliminary shaping ensures uniform force distribution during crimping, producing consistent joint strength that can be reliably measured and tested, solving the difficulty of determining pull strength while maintaining assembly simplicity
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
This approach enhances the crimp strength and reduces electromagnetic radiation leakage, providing improved interference protection and preventing unraveling, thus ensuring reliable performance and extended cable life.
Implementation Method 1
embedding the end portion of the shield in the shell
Data Source
AI summary
An electromagnetically shielded cable includes a shell having an end portion and a shield embedded in the end portion of the shell. A method of forming the electromagnetically shielded cable is also provided. The method includes the steps of inserting the end portion of the shield into a mold, and embedding the end portion of the shield in the shell. In one embodiment, the shell includes a connector extending from the shell and through an opening defined by the shield for embedding the shield in the shell. In another embodiment, the shield is embedded directly in the end portion of the shell.