Shielded Wire Cable Splice Sleeve for Electrical Continuity
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Solution Overview
Problem
Existing methods for splicing shielded wire cables, particularly in high voltage applications like electric and hybrid electric vehicles, face complexity in maintaining electrical continuity and isolation of shield conductors, especially in configurations like Y-splices, which complicates the interconnection process and increases material usage.
Innovation Solution
A wire harness assembly and method that involves joining center conductors of shielded wire cables within a conductive sleeve, using crimping and soldering to create electrical continuity between shield conductors while maintaining insulation separation, and enclosing the assembly in an outer insulator for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shield conductors are cut back and interconnected in traditional splicing methods, then electrical continuity of shield conductors is maintained, but the splicing process becomes complicated and material usage increases
Solution Approach 1:
The patent combines the center conductor connection and shield conductor connection into a single integrated splicing device. The body simultaneously receives multiple cable assemblies and provides both center conductor splicing and shield conductor interconnection in one operation, eliminating the need for separate cutting and connecting steps required by traditional methods.
Solution Approach 2:
The splicing device performs multiple functions within a single structure: it splices center conductors, connects shield conductors, provides insulation, and maintains cable positioning. This multi-functional design replaces the multiple separate components and steps needed in conventional splicing approaches.
2Adaptability or versatility
If traditional splicing methods are used for Y-splice configurations, then multiple electrical loads can be connected, but the process becomes further complicated and requires more materials
Solution Approach 1:
The splicing device merges multiple cable terminations into a single integrated structure, allowing one, two, or three cable assemblies to be connected simultaneously. This consolidation reduces the number of separate connectors, insulation pieces, and fastening elements needed compared to traditional Y-splice methods.
Solution Approach 2:
The device is designed with modular internal structures including separate cavities for center conductors and shield conductors, allowing flexible accommodation of different Y-splice configurations while maintaining a compact overall form that minimizes material usage.
3Reliability
If separate insulation pieces are used for each cable in traditional splicing, then electrical isolation is maintained, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent uses a single molded insulative body that integrates multiple insulation functions. This single piece provides electrical isolation between different conductors and cables while simultaneously serving as the structural housing for the entire splicing assembly, eliminating the need for multiple separate insulation components.
Solution Approach 2:
The insulative body performs multiple functions: it electrically isolates conductors, mechanically supports the splicing structure, positions cable assemblies, and provides environmental protection. This multi-functional design replaces numerous separate parts with a single integrated component.
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
This solution simplifies the splicing process, reduces cable length and weight, lowers material costs, and minimizes packaging space by allowing multiple electrical loads to share a single fuse, while ensuring electrical continuity and isolation of shield conductors.
Implementation Method 1
a conductive sleeve defining a longitudinal axis and a first axial passage enclosing a portion of the first, second, and third shield conductors and defining a first contact attached to the first shield conductor, a second contact attached to the second shield conductor, and a third contact attached to the third shield conductor
Implementation Method 2
an outer insulator sealably engaging the first, second, and third insulative jackets and enclosing the conductive sleeve
Implementation Method 3
using crimping and soldering to create electrical continuity between shield conductors
Implementation Method 4
using crimping and soldering to create electrical continuity between shield conductors
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A wire cable assembly (150), such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables (110, 112, 114) spliced together. The center conductors (116) are joined together and enclosed in an inner insulator (152). The shield conductors (130) of the cable are joined by an electrically conductive sleeve (160) enclosing the inner insulator (152) and attached to the shield conductors (130) of the shielded wire cables (110). The sleeve (160) separates the outer insulating layers of the shielded wire cables (110). The sleeve (160) is encased by an outer insulator (182) that is sealed to the outer insulating layers of the shielded wire cables (110). A method (300) of splicing shielded wire cables (110) together is also presented.