Splice Shield Design for High-Voltage Junctions
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Solution Overview
Problem
Existing wire harness splitter assemblies, such as junction blocks, are complex, expensive, and bulky, with connections prone to corrosion and interference from environmental factors, leading to increased resistance and potential contact issues.
Innovation Solution
A splice device with a metal splice shield that encloses a junction between two conductive conduits, using ferrules and ring collars to mechanically and electromagnetically shield the connection, and a protective cover to prevent moisture and contaminants, while simplifying assembly and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional junction blocks are used to split wires, then wire connection functionality is achieved, but device complexity and assembly cost increase significantly
Solution Approach 1:
The invention divides the connection system into modular components: a reusable splice shield that can be detached and reused across multiple connections, and individual ferrules for each wire pair. This segmentation allows the complex shielding function to be separated from the connection function, reducing overall assembly complexity while maintaining connection reliability.
Solution Approach 2:
The splice shield serves multiple functions simultaneously: it provides electromagnetic shielding, mechanical protection, and a standardized mounting interface for ferrules. This multi-functionality eliminates the need for separate junction blocks and shielding components, reducing device complexity and assembly steps.
2Adaptability or versatility
If traditional junction blocks are used, then wire splitting functionality is achieved, but spatial occupation and packaging difficulty increase
Solution Approach 1:
The ferrules are nested within the splice shield structure, with each ferrule positioned in a dedicated cavity or slot within the shield. This nesting arrangement allows multiple wire connections to be compactly organized within a small volume, enabling wire splitting functionality without requiring large spatial occupation.
3Ease of manufacture
If wire connections are exposed to environment, then installation simplicity is maintained, but corrosion and resistance increase over time
Solution Approach 1:
The splice shield acts as a protective shell that encloses the wire connections and ferrules. This thin-walled structure provides environmental protection against moisture and contaminants while maintaining a compact form factor that does not significantly increase the overall size of the connection assembly.
Solution Approach 2:
The ferrules serve as intermediary components between the wires and the splice shield. These ferrules provide a protected interface point that is both electrically conductive and mechanically robust, allowing wire connections to be made within the protected environment of the splice shield while maintaining electrical performance.
4Object-affected harmful factors
If electromagnetic shielding is added to protect junctions, then environmental interference is reduced, but assembly complexity increases
Solution Approach 1:
The electromagnetic shielding function is merged with the mechanical protection and mounting functions in the splice shield. By combining these functions into a single integrated component rather than separate elements, the assembly process is simplified while maintaining effective electromagnetic shielding protection.
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 effective electromagnetic shielding, corrosion protection, and reduced assembly complexity, resulting in a compact, cost-effective, and reliable high-voltage splice device that minimizes environmental interference.
Implementation Method 1
The splice shield is fixed to the plurality of ring collars and serves to electromagnetically shield the junction from an external environment
Implementation Method 2
a junction that is an ultrasonic weld joint formed by bonding the first electrically conductive conduit to the second electrically conductive conduit by ultrasonic welding
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention concerns a method for assembling a splice device (10), comprising: fixing a splice shield (18) to a first electrically conductive conduit (34) and to a second electrically conductive conduit (38) at a location covering a junction (16) formed between the first electrically conductive conduit (34) and a portion of the second electrically conductive conduit (38); mechanically securing the first electrically conductive conduit (34) and the second electrically conductive conduit (38) together with the splice shield (18); and electromagnetically shielding the junction (16) from an external environment with the splice shield (18); wherein the splice device (10) includes a plurality of ferrules (30) along a portion of the first electrically conductive conduit (34) and a portion of the second electrically conductive conduit (38), each of the plurality of ferrules (30) having a flanged portion (110) acting as a stop which directly contacts the splice shield (18) to retain the splice shield (18) on the first electrically conductive conduit (34) and the second electrically conductive conduit (36)