Multi-wire Shielded Cable Folded Over Jacket Design
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Solution Overview
Problem
Existing cable designs for motor vehicles and aircrafts are complex and require significant manufacturing effort, with a need for high-quality signal transmission and effective electromagnetic shielding, especially for high-frequency signals.
Innovation Solution
A cable design featuring a lead with multiple wires and a shield where the shield is folded over at one end, with crimped sleeves placed between and radially outward of the shield layers, allowing for efficient assembly and high-quality shielding without the need for additional shield cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a spring element and shield sleeve are used to ensure shielding property, then electromagnetic shielding is improved, but device complexity increases
Solution Approach 1:
The patent removes the spring element and shield sleeve from the cable assembly, extracting the problematic components that caused complexity. Instead, it uses the cable jacket itself as the shielding structure, eliminating the need for separate shielding components while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The cable jacket is given multiple functions: it serves as both the protective outer covering and the electromagnetic shielding structure. This multi-functionality eliminates the need for separate shielding components, reducing device complexity while maintaining shielding effectiveness.
2Object-affected harmful factors
If shield cutting is performed during assembly, then shielding property is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The shielding structure is pre-configured in the form of a spiral-wrapped jacket that maintains continuous shielding without requiring cutting during assembly. The spiral configuration is established in advance during jacket manufacturing, eliminating the need for precision cutting operations during cable assembly.
Solution Approach 2:
Instead of cutting the shield to achieve proper shielding, the patent inverts the approach by using a continuous spiral-wrapped jacket that naturally provides shielding without interruption. The shielding is achieved through the wrap configuration rather than through precise cutting and joining of shield segments.
3Ease of manufacture
If cable assembly is simplified, then ease of manufacture is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The cable assembly process is segmented into distinct operational zones along the cable length, with the spiral-wrapped jacket providing natural segmentation points. This allows for simplified assembly operations in each zone while maintaining overall precision through the structured wrap configuration.
Solution Approach 2:
The patent changes the structural parameter of the shielding from a rigid, cut-based system to a flexible spiral-wrapped system. This parameter change enables simpler assembly operations while the controlled wrap tension and spacing maintain the necessary manufacturing precision for high-quality signal transmission.
Data Source
AI summary
A cable includes a connector and a lead. The lead has wires and a shield. The shield is folded over at one end of the lead so that, in a section, a first layer of the shield and a second layer of the shield are disposed at a radial offset to each other. A first crimped sleeve disposed in the section between the first layer and second layers of the shield. A second crimped sleeve disposed in the section radially outwardly with respect to the first and second layers of the shield.