Shielded Flexible Electrical Connection Member for Moisture Resistance
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Solution Overview
Problem
Existing electrical connection members are not flexible enough to accommodate relative motion between power sources and equipment, are not resistant to moisture and dirt, and suffer from signal interference in challenging environments.
Innovation Solution
A method involving laminate structures with a conductive layer interposed between non-conductive layers, forming a Faraday cage, and etching portions of the non-conductive layers to expose conductive surfaces for grounding connections, while using adhesives for bonding and forming flanges to create a water-resistant and interference-minimizing connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electrical connection member is made flexible to accommodate motion, then adaptability is improved, but structural integrity and protection against moisture/dirt deteriorate
Solution Approach 1:
The patent employs a multi-layer composite structure consisting of an inner flexible conduit for electrical conductors, a middle protective layer (such as heat-shrinkable tubing or adhesive layer), and an outer laminate structure with conductive and non-conductive layers. This composite construction allows the connection member to remain flexible while providing robust protection against moisture, dirt, and environmental factors.
Solution Approach 2:
The patent utilizes flexible protective coverings including heat-shrinkable tubing that can be stretched and shrunk to conform to the conduit, adhesive layers that bond to the conduit surface, and laminate structures with flexible non-conductive layers. These flexible shell-like structures provide environmental protection while maintaining the ability to bend and accommodate motion between power sources and electrical equipment.
2Reliability
If a protective covering is added to resist moisture and dirt, then reliability is improved, but signal interference from electromagnetic signals deteriorates
Solution Approach 1:
The patent introduces a conductive layer as an intermediary element between the inner electrical conduit and the outer non-conductive protective layers. This conductive layer forms a Faraday cage that acts as an electromagnetic shield, blocking external electromagnetic signals from interfering with the electrical conductors while allowing the outer layers to provide moisture and dirt protection.
Solution Approach 2:
The patent creates a composite laminate structure where non-conductive layers (providing water resistance) are combined with conductive layers (providing electromagnetic shielding). This composite material approach allows both functions - environmental protection and signal interference minimization - to be achieved simultaneously within a single integrated structure.
3Reliability
If multiple layers are used to provide protection and shielding, then reliability is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The patent combines multiple protective and shielding functions into an integrated laminate structure where the conductive layer and non-conductive layers are bonded together to form a single composite component. The conductive layer is attached to the inner conduit, and the non-conductive layers are attached to the conductive layer, creating a unified multi-functional structure that provides mechanical protection, electromagnetic shielding, and environmental resistance in one manufacturing step.
Solution Approach 2:
The patent employs preliminary actions in the manufacturing process, such as pre-forming the conductive layer into a tubular shape that fits over the conduit, pre-applying adhesive layers to the conduit surface, and using heat-shrinkable tubing that is pre-formed and then shrunk into place. These preliminary preparations simplify the final assembly process and reduce manufacturing complexity despite the multi-layer structure.
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 solution provides a flexible, water-resistant electrical connection member that minimizes signal interference and withstands wear and friction, suitable for harsh environments.
Implementation Method 1
bonding together the flanges of the first and second laminate structures to form a faraday cage around the electrical conduit
Implementation Method 2
the bonding comprises applying an adhesive to the flanges of the first and second laminate structures and compressing the flanges
Implementation Method 3
etching a portion of the first non-conductive layer of the first laminate structure from a first direction; wherein the etching removes material from the first non-conductive layer
Data Source
Figure 1a~1c
Figure 2
Figure 3
AI summary
There is disclosed a method for producing an electrical connection member comprising a textile cover and an inner electrical conduit, wherein the method comprises the steps of; positioning an electrical conduit in between first and second laminate structures, wherein the first and second laminate structures have a greater width than the electrical conduit and extend to form flanges either side of the electrical conduit, wherein each laminate structure is formed of a conductive layer interposed between a first and a second non-conductive layer, and wherein the first and the second laminate structures are textile structures; bonding together the flanges of the first and second laminate structures to form a faraday cage around the electrical conduit; etching a portion of the first non-conductive layer of the first laminate structure from a first direction; wherein the etching removes material from the first non-conductive layer of the first laminate structure; exposing a first surface of the conductive layer of the first laminate structure in the first direction, wherein the exposed first surface enables contact for a first grounding connection.