Shielded Cable Junction Assembly With Integrated Shield Connection
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Solution Overview
Problem
Existing shielded electric cable assemblies are difficult to manufacture due to complex and cumbersome connections between shield conductors and insulators, leading to inefficiencies in production.
Innovation Solution
A shielded electric cable assembly design featuring a first and second shielded electric cable with conductors joined by an inner insulator, partially covered by shield conductors, and a shield element, housed within a protective structure with sealing elements to ensure easy assembly and reliable conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ferrules and ring collars are used to connect shield conductors and insulators, then electrical conductivity is achieved, but manufacturing complexity increases significantly
Solution Approach 1:
The patent merges the ferrule and ring collar into a single integrated shield connector component. This connector combines the electrical connection function (formerly ferrule) with the mechanical attachment function (formerly ring collar) into one piece that directly couples the shield conductor to the insulator, eliminating the need for multiple separate components and reducing assembly steps.
Solution Approach 2:
The shield connector is designed as a multi-functional component that simultaneously provides electrical conductivity, mechanical support, and sealing functions. This universal component replaces multiple specialized parts (ferrule for electrical contact, ring collar for mechanical attachment) with a single element that performs all necessary functions.
2Reliability
If multiple components (ferrules, ring collars, shield elements) are assembled, then reliable electrical connection is achieved, but production time increases
Solution Approach 1:
The patent segments the cable assembly into distinct functional modules: the shield connector as one module, the shield element as another, and the insulator as a separate component. This modular segmentation allows each component to be manufactured independently and assembled in a simplified sequence, reducing overall production time while maintaining connection reliability.
Solution Approach 2:
The shield connector is pre-formed with integrated electrical contact surfaces and mechanical attachment features before assembly. This preliminary preparation of the connector component eliminates the need for on-site assembly of multiple smaller parts, thereby reducing production time while ensuring reliable electrical connection.
3Object-affected harmful factors
If shield conductors fully cover the insulator, then electromagnetic shielding is improved, but ease of connection between shield element and shield conductors deteriorates
Solution Approach 1:
The shield conductor is designed with non-uniform coverage of the insulator, providing full coverage in regions where electromagnetic shielding is critical (lateral surfaces) while leaving the axial ends partially exposed. This local quality variation optimizes shielding performance where needed while facilitating easy connection of the shield element at the exposed ends.
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 electrical conductivity between shield conductors, enhancing the production efficiency and sealing effectiveness of the cable assembly.
Implementation Method 1
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
Implementation Method 2
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 3
The inner insulator is a heat shrink tube
Data Source
AI summary
A shielded electric cable assembly including a first shielded electric cable having a first shield conductor covering a wire and being covered by a first insulative jacket. The shielded electric cable assembly further includes a second shielded electric cable having a second shield conductor covering a wire and being covered by a second insulative jacket, where the conductors of the first and second shielded electric cables are joined forming a junction. The shielded electric cable assembly further includes an inner insulator covering the junction, a shield element covering the inner insulator in contact to the first and second shield conductors, and a housing covering the shield element and the first and second insulative jackets. A first and a second sealing element are provided between the housing and the first and second insulative jackets.