Shielded Cable Splice Assembly for Electromagnetic Sealing
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Solution Overview
Problem
Existing shielded electric cable assemblies face challenges in easy manufacturing and reliable electromagnetic sealing, particularly when dealing with different materials and elasticities of insulative jackets.
Innovation Solution
A shielded electric cable assembly design featuring a first and second shielded electric cable with conductors joined by an inner insulator, where the shield conductors partially cover the insulator and a shield element is in electrical contact, housed within a structure with sealing elements and cable bushings to ensure reliable conductivity and sealing, and optionally using sealing rings for enhanced sealing on flexible materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ferrules and ring collars are used to connect shield conductors, then electromagnetic sealing is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the ferrule and ring collar into a single integrated shield connector component. This connector simultaneously provides mechanical connection and electromagnetic sealing functions, eliminating the need for separate ferrules and ring collars, thus reducing manufacturing complexity while maintaining reliable electromagnetic sealing.
Solution Approach 2:
The shield connector is designed as a multi-functional component that performs multiple tasks: mechanical connection of shield conductors, electrical conductivity, and electromagnetic sealing. This universal component replaces multiple specialized components (ferrules for connection, ring collars for sealing), simplifying the manufacturing process while achieving the same technical effects.
2Reliability
If multiple components (ferrules, ring collars) are assembled, then reliable connection is achieved, but manufacturing time increases
Solution Approach 1:
By combining multiple assembly steps into a single integrated component, the patent reduces the number of assembly operations required. The shield connector is pre-assembled as a single unit, eliminating sequential assembly steps and reducing manufacturing time while maintaining connection reliability.
Solution Approach 2:
The shield connector is prepared and pre-assembled before installation, with all connection and sealing features already in place. This preliminary preparation of the integrated connector eliminates the need for on-site assembly of multiple components, reducing manufacturing time while ensuring reliable connection.
3Reliability
If shield conductors fully cover the insulator, then electromagnetic shielding is improved, but ease of connection decreases
Solution Approach 1:
The shield conductor is designed with non-uniform coverage: it fully covers the insulator in regions requiring electromagnetic shielding, while leaving portions exposed at connection points. This local variation in coverage quality maintains shielding effectiveness where needed while facilitating easy connection where accessibility is required.
Solution Approach 2:
The shield conductor coverage is segmented into different zones: fully covered regions for electromagnetic shielding and partially exposed regions for connection access. This segmentation allows the insulator to serve dual purposes of electrical insulation and connection facilitation, while maintaining shielding effectiveness in critical areas.
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
Facilitates easy manufacturing and reliable electromagnetic sealing, ensuring effective conductivity and protection against environmental interference, even with varying materials and elasticities of insulative jackets.
Implementation Method 1
a shield element covering at least partially axially the inner insulator in electrical conductive contact to the first shield conductor and the second shield conductor
Implementation Method 2
a first sealing element between the housing and the first insulative jacket; and a second sealing element between the housing and the second insulative jacket
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Shielded electric cable assembly comprising: - a first shielded electric cable (1) having a first shield conductor (8) covering a wire (2, 5) and being covered by a first insulative jacket (9); - a second shielded electric cable (10) having a second shield conductor (17) covering a wire (11, 14) and being covered by a second insulative jacket (18), - the conductors (3, 6) of the first and second shielded electric cables (1, 10) are joined forming a junction (28, 29); - an inner insulator (30) covering the junction (28, 29); - a shield element (34) covering the inner insulator (30) in contact to the first and second shield conductors (8, 17); - a housing (35) covering the shield element (34) and the first and second insulative jackets (9, 18); - a first and a second sealing element (36, 37) between the housing (35) and the first and second insulative jackets (9, 18), respectively.