Shielded Cable With Segmented Crimp Sleeve For HF Signals
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Solution Overview
Problem
Existing cables for transmitting high-frequency signals in vehicles and aircrafts face challenges in achieving effective electromagnetic shielding while maintaining low production costs and ensuring high-quality signal transmission.
Innovation Solution
A shielded cable design featuring a conductive sleeve with specific crimp ridge configurations and sections, allowing for uniform press-fitting and enhanced crimping connections, which reduces electromagnetic interference and transition resistance, and includes a crimping device with offset crimping indenters for precise crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielded cable design with uniform crimping is used, then electromagnetic shielding is improved, but production complexity increases
Solution Approach 1:
The sleeve is divided into multiple sections along its longitudinal axis, with each section having different crimping characteristics. Specifically, the sleeve includes a first section with first crimp ridges, a second section with second crimp ridges, and a third section without crimp ridges. This segmentation allows different portions of the shield to be crimped with different pressures and patterns, optimizing electromagnetic shielding while managing production complexity.
Solution Approach 2:
Different regions of the sleeve are given different local qualities through varying crimp ridge configurations. The first and second sections have crimp ridges for strong electrical connection, while the third section remains smooth for uniform press-fitting. This local differentiation ensures that each region performs its specific function optimally, balancing shielding effectiveness with manufacturing feasibility.
2Strength
If multiple crimp ridges are formed in the sleeve, then crimp connection strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The crimping process is segmented into distinct sections along the sleeve length. Each section has clearly defined crimp ridges at specific positions, with the third section intentionally left without crimp ridges. This segmentation simplifies the manufacturing process by providing clear zones for and against crimping, reducing the precision burden compared to uniform multi-ridge designs.
Solution Approach 2:
The sleeve geometry is pre-designed with designated crimp zones and non-crimp zones before the actual crimping process. The third section is specifically configured without crimp ridges to ensure uniform press-fitting, while the first and second sections are pre-marked for crimp ridge formation. This preliminary structural preparation guides the crimping operation and reduces real-time precision requirements.
3Ease of manufacture
If the sleeve has uniform diameter throughout, then ease of manufacture is improved, but shielding effectiveness decreases
Solution Approach 1:
The sleeve is segmented into three distinct sections with different diameters and crimping characteristics. The first section has a larger diameter for initial shield insertion, the second section has a reduced diameter for crimping operations, and the third section maintains a specific diameter for uniform press-fitting without crimp ridges. This segmentation allows the sleeve to be manufactured in stages, balancing ease of production with shielding performance.
Solution Approach 2:
Different sections of the sleeve have different local diameters optimized for their specific functions. The varying diameter profile ensures that each region contributes optimally to both manufacturing ease and shielding effectiveness, rather than using a uniform diameter that would compromise one or the other.
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
The cable achieves high electromagnetic compatibility, reduced radiation emission, and increased tensile strength, ensuring reliable high-frequency signal transmission with improved shielding and reproducible production quality.
Implementation Method 1
The crimping is provided such that the sleeve has at least one crimp ridge within the first section in the first sleeve half and does not have a ridge in the second sleeve half
Data Source
AI summary
A cable for transmitting HF signals includes a shield, at least one wire, and an electrically conductive sleeve. The sleeve includes a first and a second geometrical sleeve half as well as a first section and a second section. The sleeve is connected to the shield by crimping, such that the sleeve has at least one crimping ridge within the first section in the first sleeve half, and has no crimping ridges in the second sleeve half. It also has no crimping ridges within the second section in the first sleeve half and has at least one crimping ridge in the second sleeve half.