Shielded Wire Cable Splice Using Segmented Contacts
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Solution Overview
Problem
Existing methods for splicing shielded wire cables, particularly in high voltage applications, face complexity in maintaining electrical continuity and mechanical integrity, especially in configurations like Y-splices, due to the need to cut and reconnect shield conductors, which can be cumbersome and inefficient.
Innovation Solution
A wire harness assembly and method that involves joining core conductors and separating insulative jackets to create a conductive path between shield conductors using crimped contacts and ferrules, with optional soldering, and encasing in heat shrinkable tubing to ensure electrical and mechanical connectivity while reducing material usage and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shield conductors are cut back and reconnected using traditional methods, then electrical continuity is maintained, but the splicing process becomes complicated and time-consuming
Solution Approach 1:
The shield conductor connection is segmented into separate contact points (first contact, second contact, third contact) that can be independently attached to individual shield conductors. Each contact is crimped to a ferrule that is then attached to the respective shield conductor, allowing modular assembly rather than requiring a single complex connection structure
Solution Approach 2:
Ferrules serve as intermediary components between the contacts and shield conductors. The ferrules simplify the attachment process by providing a standardized interface that can be crimped to both the contact and the shield conductor, reducing the complexity of directly connecting contacts to braided shield conductors
2Reliability
If traditional splicing methods with multiple components are used, then electrical continuity is achieved, but material requirements and costs increase
Solution Approach 1:
The conductive sleeve combines multiple functions into a single component: it provides the conductive path for shield continuity, houses the contacts and ferrules, and works with the heat shrinkable tubing to provide mechanical protection and sealing. This integration reduces the number of separate components and materials needed compared to traditional splicing methods
Solution Approach 2:
The heat shrinkable tubing with adhesive liner serves multiple functions: it mechanically secures the conductive sleeve and contacts in place, provides electrical insulation, creates a seal to protect the splice, and bonds the entire assembly to the cable jackets. This multi-functionality reduces the need for additional separate components
3Reliability
If shield conductors are interconnected in Y-splice configurations, then electrical continuity is maintained across multiple cables, but the splicing process becomes even more complicated
Solution Approach 1:
The Y-splice configuration is simplified by segmenting the shield conductor connections into individual contacts (first, second, third contacts) that can be independently attached to each cable's shield conductor. This modular approach allows each cable to be connected separately to the conductive sleeve, making the multi-cable splice as manageable as individual splices
Solution Approach 2:
The contacts are pre-attached to the conductive sleeve before final assembly, and the ferrules are pre-prepared for attachment to shield conductors. This preliminary preparation of connection components simplifies the actual splicing operation, as the complex connection hardware is already assembled and ready for installation
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 simplifies the splicing process by maintaining electrical continuity and mechanical integrity, reducing material requirements, and enhancing sealing, thus lowering costs and complexity in high voltage applications like electric vehicles.
Implementation Method 1
disposing the flexible conductive layer and portions of the first, second, and third insulative jacket within the section of heat shrinkable tubing
Implementation Method 2
heating the solder paste until it reflows, thereby soldering the first, second, and third contacts to the first, second, and third shield conductors respectively
Implementation Method 3
crimping the first, second, and third ferrule to the first, second, and third contacts respectively, thereby attaching the first, second, and third contacts to the first, second, and third shield conductors respectively
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method (400) of splicing shielded wire cables (110, 112, 114) includes the steps of providing a first, second, and third shielded wire cable (110, 112, 114) each having a core conductor (116, 118, 120) axially surrounded by a shield conductor (130, 132, 134) which is axially surrounded by an insulative jacket (124, 126, 128), providing a flexible insulation layer (510), a flexible conductive layer (518), and a section of dual wall heat shrink tubing (step 410). The first portion of the flexible insulation layer (510) is wrapped about the joined first, second, and third core conductors (116, 118, 120) (step 412). The flexible conductive layer (518) is wrapped about the first, second, and third shield conductors (130, 132, 134) (step 422). The flexible conductive layer (518) and portions of the first, second, and third insulative jacket (124, 126, 128) are disposed within the section of dual wall heat shrink tubing (524) (step 428), thus forming a shielded wire cable splice (528).