Shielded Cable Quick Disconnect EMI Leakage
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Solution Overview
Problem
Electrical cables used in connecting components face challenges with Electromagnetic Interference (EMI) leakage and require efficient disconnection mechanisms, particularly in applications like helmets and control boxes where quick and secure connections are necessary.
Innovation Solution
The cable system incorporates shielded twisted wire pairs with a separate shielding layer and a quick disconnect connector pair, where the shielding is connected to an inner shell to maintain the ground path and reduce EMI leakage, and the outer shell facilitates a 10-15 pound disconnect force for easy engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If shielding is removed from wire pairs near connectors to expose wires for connection, then ease of connection is improved, but EMI leakage increases
Solution Approach 1:
An inner shell acts as an intermediary structure between the exposed wire pairs and the external environment. The inner shell encloses the exposed portions of wire pairs at the connector interface, providing EMI shielding where the wire pair shielding is removed, thus preventing EMI leakage while allowing proper electrical connections.
Solution Approach 2:
The shielding structure is segmented into multiple components: individual wire pair shields that are removed near connectors, and an inner shell that provides localized shielding at the connector interface. This segmentation allows selective shielding where needed while maintaining ease of connection.
2Object-affected harmful factors
If shielding is kept on wire pairs near connectors, then EMI leakage is reduced, but ease of connection deteriorates
Solution Approach 1:
The shielding is selectively removed (taken out) from the wire pairs in the regions where connectors need to access the wires. This extraction of shielding material from specific locations enables straightforward wire connections while the inner shell provides necessary EMI protection at the interface.
3Ease of operation
If outer shell is designed with slots for quick disconnect, then ease of operation is improved, but structural strength deteriorates
Solution Approach 1:
The outer shell incorporates slots that enable dynamic movement and deflection of shell portions during connection and disconnection operations. This dynamic design allows the shell to flex and return to its original position, facilitating quick disconnect while maintaining overall structural integrity through the shell's resilient 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
This configuration effectively reduces EMI leakage and allows for secure, quick, and reliable connections/disconnections, ensuring reliable signal transmission and power delivery in applications like helmets and control boxes.
Implementation Method 1
The cable may include a shielding layer. The shielding layer may reduce or eliminate EMI leakage.
Implementation Method 2
The twisted pair of wires with the shield may provide controlled impedance for the wires.
Implementation Method 3
In order to maintain the ground path for the shielding of the shielded twisted wire pairs, the shielding is connected to the shell. The shielding is connected to the shell to maintain the ground along the signal paths for the wires.
Data Source
AI summary
The cable attaches a first component and a second component using a quick disconnect connector pair. The cable includes a twisted pair of wires with a separate shield. A portion of the shielding near the connector is removed to expose the wires and assemble the wires to the connector. To reduce the EMI leakage, the inner shell encloses the exposed portions of the wires. In order to maintain the ground path for the shielding of the shielded twisted wire pairs, the shielding for the twisted wire pairs is connected to the shell. The outer shells facilitate the quick disconnect feature. The outer shell includes one or more slots. The slot allows a portion of the outer shell to become a cantilever beam. The beam deflects during disengagement and engagement with the outer shell.