Shielded Cable Termination Ring and Ferrule for Electrical Isolation
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Solution Overview
Problem
Existing shielded cable terminations in electric or hybrid vehicles face issues where parts of the outer conductor can make electrical contact with the inner conductor and/or the terminal, leading to unreliable connections.
Innovation Solution
A method involving stripping and ferrule mounting steps, including the use of a dielectric termination ring mounted over the inner insulator to maintain the outer conductor away from the free end, and a ferrule assembly comprising a conductive outer and dielectric inner ferrules to prevent electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional termination methods are used without additional insulation components, then the device complexity is reduced, but electrical contact between outer conductor and inner conductor/terminal cannot be prevented
Solution Approach 1:
A dielectric tube is introduced as an intermediary component between the outer conductor and the inner conductor/terminal. This dielectric tube acts as a mediator that provides electrical insulation and prevents harmful electrical contact, thereby resolving the contradiction between maintaining simple structure and ensuring reliable insulation.
Solution Approach 2:
The termination structure is segmented into distinct functional zones: the dielectric tube provides insulation, the outer conductor provides shielding, and the inner conductor provides signal transmission. This segmentation allows each component to perform its specific function effectively, preventing electrical contact while maintaining overall structural organization.
2Reliability
If the outer conductor is folded back to maintain insulation, then the manufacturing process is simplified, but electrical contact may still occur and the cable length is reduced
Solution Approach 1:
The dielectric tube serves as a mediator that eliminates the need to fold back the outer conductor. By placing the dielectric tube over the inner conductor and positioning it within the folded-back outer conductor, the tube maintains electrical insulation without requiring the outer conductor to be folded, thus preserving cable length while ensuring insulation reliability.
3Strength
If ferrules are used to connect outer conductor to connector housing, then mechanical strength is improved, but electrical contact between outer conductor and terminal may occur
Solution Approach 1:
The dielectric tube acts as an intermediary barrier between the outer conductor and the terminal. Even when ferrules are used to provide mechanical strength for connecting the outer conductor to the connector housing, the dielectric tube maintains electrical insulation and prevents electrical contact between the outer conductor and the terminal, thereby resolving the contradiction between mechanical strength and electrical insulation.
Data Source
Figure 1~3
Figure 4A~4D
Figure 4E~6
AI summary
A method of terminating a shielded cable having an inner conductor (21), an inner insulator (22) surrounding the inner conductor (21), an outer conductor (23) surrounding the inner insulator (22), and an outer insulator (24) surrounding the outer conductor (23), this method comprising a step of mounting a termination ring (6), formed of a dielectric material, over the inner insulator (22) and between a free end of the shielded cable and the outer conductor (23) to maintain the outer conductor (23) away from the free end.