Stripped Conductor Cable with Collar Ring Sealing
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Solution Overview
Problem
Existing cables for motor vehicles and aircraft have complex structures, leading to high production costs and complex assembly, while also being prone to electromagnetic interference and signal degradation due to their design.
Innovation Solution
A multi-core cable design featuring a line with radially arranged jackets and a coupling housing comprising a collar ring, pin housing, and sealing element, where the conductors are stripped to serve as contact pins, maintaining consistent spacing and minimizing interference, and assembled using a press or adhesive connection for secure sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a complex cable structure with individual wires and shielding is used, then electromagnetic immunity is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent extracts and eliminates the shielding layer and individual wire insulation from the cable structure. By using solid conductors without individual wire insulation and removing the shielding layer entirely, the design achieves electromagnetic immunity through a simplified geometry-based approach rather than traditional shielding methods.
Solution Approach 2:
Instead of using insulation to protect conductors and shielding to block electromagnetic interference, the patent inverts the approach by using the bare solid conductor geometry itself to achieve both electrical insulation (through air gaps) and electromagnetic immunity. The collar ring with its specific geometry serves multiple functions traditionally handled by separate components.
2Reliability
If traditional cables with individual wires and insulation are used, then electrical insulation is maintained, but production cost and assembly complexity increase
Solution Approach 1:
The patent merges multiple functions into the collar ring component: it provides electrical insulation, mechanical support, positioning of conductors, and sealing. By combining these functions into a single geometrically optimized component rather than using separate insulation layers and structural elements, manufacturing is simplified while reliability is maintained.
Solution Approach 2:
The solid conductors serve their own insulation needs through the air gaps created by the collar ring geometry, eliminating the need for separate insulation materials. The collar ring's geometry automatically provides the necessary electrical isolation without requiring additional insulating components.
3Ease of operation
If conductors are stripped to serve as contact pins, then assembly is simplified, but conductor spacing consistency must be maintained
Solution Approach 1:
The collar ring is designed with pre-formed geometric features (protrusions and recesses) that automatically position the solid conductors at correct spacing during assembly. This preliminary geometric configuration ensures spacing consistency is maintained without requiring precision machining of each conductor individually.
Solution Approach 2:
The patent changes the physical state of conductors from insulated wires to stripped solid pins, and uses the collar ring's geometry to control the spacing parameter. The geometric constraints of the collar ring automatically maintain consistent conductor spacing, transforming a precision manufacturing challenge into a geometric assembly feature.
Data Source
Figure 1
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AI summary
The invention relates to a cable comprising a conductor (1) and a coupling housing (2). The conductor (1) comprises several cores (1.1; 1.2) and a sheath (1.3). The several cores (1.1; 1.2) each have a conductor (1.11; 1.21) and insulation (1.12; 1.22) surrounding the conductor (1.11; 1.21), the conductors (1.11; 1.21) being stripped at one end of each core (1.1; 1.2). The coupling housing (2) comprises a locking ring (2.1), a pin housing (2.2), and a sealing element (2.3). The locking ring (2.1) surrounds the pin housing (2.2) and the sheath (1.3) and is fixed to the sheath (1.3). The pin housing (2.2) surrounds the stripped conductors (1.11; 1.21) of the wires (1.1; 1.2). The sealing element (2.3) is arranged between the retaining ring (2.1) and the pin housing (2.2). The conductors (1.11; 1.21) are made of solid, coated steel wire, and the stripped ends of the conductors (1.11; 1.21) can be used as contact pins.