Splicing Shielded Wire Cables Using Conductive Bus Bar
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing splicing devices for shielded wire cables require a 'fan out' of core conductors, increasing the overall length and complexity of the splicing process, especially in configurations like Y-splice or H-splice, where electrical continuity of shield conductors is challenging to maintain.
Innovation Solution
A wire harness assembly and method that uses a conductive bus bar to weld exposed core conductors and a conductive sleeve to interconnect shield conductors, with a thermoplastic post providing an interference fit within a longitudinal slot to secure the bus bar, reducing the overall length and complexity of the splicing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive sleeve is used to interconnect shield conductors in a one-to-many splicing configuration, then electrical continuity of shield conductors is achieved, but the overall length of the splicing device increases and the splicing process becomes more complex
Solution Approach 1:
The splicing device is divided into modular components: a body portion with a cavity for receiving cable ends, and a conductive sleeve that can be separately positioned and connected. This segmentation allows the conductive sleeve to be independently installed to establish shield conductor continuity without complicating the overall splicing procedure.
Solution Approach 2:
The conductive sleeve acts as an intermediary component that facilitates electrical continuity between shield conductors of multiple cables. By introducing this intermediate element, the patent simplifies the connection process compared to direct interconnection methods, as the sleeve provides a standardized interface for attaching to ferrules on each cable.
2Ease of manufacture
If shield conductors are cut back from spliced ends to join center conductors, then center conductor connection is achieved, but the interconnection of shield conductors becomes complicated
Solution Approach 1:
The patent separates the connection tasks for center conductors and shield conductors into distinct operational zones. Center conductors are joined within the body portion cavity, while shield conductors are connected via the conductive sleeve system. This segmentation allows each type of conductor to be handled independently without interfering with the other, simplifying the overall process.
Solution Approach 2:
The conductive sleeve serves as an intermediary that simplifies shield conductor interconnection. Instead of requiring complex manual manipulation of cut-back shield conductors, the sleeve provides a standardized mechanism with ferrule attachment points that make shield interconnection as straightforward as center conductor splicing.
3Ease of manufacture
If a fan out configuration is used for core conductors in splicing, then electrical connection is achieved, but the length of cable required increases and the splicing device length increases
Solution Approach 1:
The patent transitions from a traditional linear fan-out arrangement to a three-dimensional compact configuration. The body portion cavity accommodates cable ends in a stacked or clustered arrangement, allowing core conductors to be connected vertically or in multiple layers rather than spreading them out horizontally. This dimensional change dramatically reduces the overall device length while maintaining effective conductor connection.
Solution Approach 2:
The splicing device employs a nested structure where the conductive sleeve is positioned within or adjacent to the body portion cavity, and conductors are arranged in a compact nested configuration. This nesting allows multiple conductors to occupy overlapping or adjacent spatial zones, eliminating the need for extensive fan-out and reducing the device's overall length.
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 reduces the overall length of the splicing device by 38% compared to existing methods, simplifies the splicing process, and ensures electrical continuity in shielded wire cables, particularly in high-voltage applications like electric and hybrid electric vehicles.
Implementation Method 1
The first, second, third, and fourth exposed core conductors are welded to the bus bar, thereby electrically connecting the first, second, third, and fourth exposed core conductors
Implementation Method 2
a thermoplastic post providing an interference fit within a longitudinal slot to secure the bus bar
Implementation Method 3
a conductive sleeve enclosing a portion of the first, second, third, and fourth exposed shield conductors
Data Source
AI summary
A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables that are spliced together is presented. The assembly includes a splicing device having a generally planar bus bar formed of a conductive material, wherein the exposed core conductors of the shielded wire cables are welded to the bus bar, thereby electrically interconnecting the exposed core conductors. A conductive sleeve encloses bus bar and interconnects the shield conductors of the shielded wire cables, providing shielding for the exposed core conductors and continuity for the shield conductors. An outer insulator enclosing the conductive sleeve. A method of splicing shielded wire cables using such a device is also presented herein.