Terminal Fitting Shield Crimping Segmentation
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Solution Overview
Problem
High-frequency compatible shielded cables in automotive vehicles face connection reliability issues due to deformation and distortion of braided wire shield conductors during crimping, leading to reduced compression ratios and compromised shielding functions.
Innovation Solution
A terminal fitting with deformable shield crimping pieces and a surrounding cover that locks the crimping pieces to prevent deformation, ensuring a uniform opening diameter and maintaining the shielding function, while also improving high-frequency performance by ensuring current flow and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shield crimping portion is crimped at a high compression ratio, then connection reliability is improved, but the braided wire shield conductor deforms and distorts
Solution Approach 1:
The shield crimping portion is divided into multiple independent shield crimping pieces (first and second pieces) that can be deformed separately. This segmentation allows each piece to crimp the braided wire uniformly without concentrating deformation in one location, preventing distortion while maintaining connection reliability
Solution Approach 2:
The shield crimping pieces are designed with specific local geometric features (such as curved surfaces and positioning protrusions) that concentrate the crimping force at optimal locations on the braided wire. This localized quality control ensures uniform compression without causing overall distortion of the shield conductor
2Shape
If the compression ratio of the shield crimping portion is reduced to prevent distortion, then the braided wire shield conductor maintains its shape, but the shield crimping portion opens and connection reliability deteriorates
Solution Approach 1:
The shield crimping pieces are designed to be deformable during the crimping process, allowing them to dynamically adapt to the braided wire shape. After crimping, the pieces maintain their deformed state to provide continuous holding force, preventing opening while preserving the shield conductor shape
Solution Approach 2:
The shield crimping pieces have asymmetric cross-sectional shapes with different curvature radii on inner and outer surfaces. This asymmetry creates a mechanical lock effect where the pieces tend to close onto the braided wire rather than open, maintaining connection reliability without requiring high compression ratios
3Reliability
If multiple separate components are used to achieve shielding function and current flow, then each function can be optimized independently, but the device complexity increases
Solution Approach 1:
The outer conductor is designed as an integrated structure that combines the shielding function (through the braided wire shield conductor) and the current flow path (through the outer conductor body) into a single component. This merging eliminates the need for separate shielding layers and current carriers, reducing overall device complexity while maintaining both functions
Solution Approach 2:
The outer conductor serves multiple functions simultaneously: it provides electromagnetic shielding through the braided wire, conducts electrical current, and provides structural support for the terminal fitting. This multi-functionality reduces the total number of components needed while ensuring both shielding and current flow requirements are met
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 terminal fitting ensures reliable connection and effective shielding without deforming the braided wire, enhancing high-frequency performance and simplifying configuration by integrating functions into a single component.
Implementation Method 1
two shield crimping pieces deformable along an outer periphery of a shield layer of a shielded cable
Implementation Method 2
a cover including a surrounding portion for surrounding the shield crimping pieces along outer peripheries thereof
Implementation Method 3
The body of the outer conductor may include a locking hole, and tips of the strips may enter the locking hole to be locked to the outer conductor
Implementation Method 4
an inner conductor having a center conductor crimping portion to be crimped to a center conductor of the shielded cable
Implementation Method 5
The outer conductor may include a coupling, and the center conductor crimping portion may be disposed inside the coupling. The coupling may have an opening, and the cover may close the opening and electrically contact the outer conductor
Data Source
AI summary
A terminal fitting (T) includes an inner conductor (11), an outer conductor (12) and a dielectric (13) interposed between these conductors. The inner conductor (11) is connected to a core (51) of a shielded cable (W). The outer conductor (12) includes two shield crimping pieces (45) deformable along an outer periphery of a braided wire (53) of the shielded cable (W). Further, the terminal fitting (T) includes a cover (14) including a shield-side surrounding portion (84) for surrounding the shield crimping pieces (45) along outer peripheries thereof.