Terminal Assembly Shielding Shell Elastic Arms Vibration Resistance
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Solution Overview
Problem
Existing terminal and connector assemblies for high voltage applications require complex structures, high manufacturing costs, and difficult assembly processes due to the need for compression connections between shielding shells and layers, which necessitate additional components and tools.
Innovation Solution
A terminal assembly with a cable that uses an overlapping region between the shielding shell and layer, facilitated by elastic arms and a compress ring, eliminating the need for crimping and specialized tools, and incorporating a sealing mechanism with a hoop and sealing ring retainer for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compression connection is used to connect shielding layer and shielding shell, then effective electric connection is achieved, but structure becomes complex and manufacturing cost increases
Solution Approach 1:
The patent combines the shielding sleeve and shielding bushing into a single integrated component. The shielding bushing directly connects the shielding layer to the shielding shell without requiring a separate shielding sleeve, thereby simplifying the structure while maintaining effective electric connection through compression.
Solution Approach 2:
The patent eliminates the shielding sleeve from the traditional compression connection structure, retaining only the essential shielding bushing to achieve the connection function. This extraction of unnecessary components reduces structural complexity and manufacturing cost.
2Reliability
If compression connection is used to connect shielding layer and shielding shell, then effective electric connection is achieved, but assembly process becomes troublesome and difficult
Solution Approach 1:
By integrating the shielding sleeve and shielding bushing into one component, the assembly process is simplified from multiple steps involving separate components to a single insertion and compression operation, making assembly less troublesome and difficult.
Solution Approach 2:
The patent divides the assembly process into simple sequential steps: inserting the integrated shielding bushing through the insulation layer, positioning it against the shielding shell, and compressing it with the crimping tool. This segmentation makes the assembly process more manageable and easier to perform.
3Reliability
If shielding sleeve and shielding bushing are used for connection, then electric connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the shielding sleeve and shielding bushing into a single integrated component, reducing the total number of parts that need to be manufactured, inventoried, and assembled. This consolidation directly reduces manufacturing cost while maintaining the required electric connection functionality.
Solution Approach 2:
By removing the shielding sleeve from the component list and integrating its function into the shielding bushing, the patent reduces the bill of materials and manufacturing complexity, thereby lowering overall manufacturing cost.
4Reliability
If traditional compression connection structure is used, then shielding function is achieved, but assembly workstation design becomes complex
Solution Approach 1:
The integrated shielding bushing requires a simpler workstation design compared to the traditional multi-component system. The workstation only needs to accommodate a single insertion and compression operation rather than managing multiple components and their respective positioning requirements.
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 structure, reduces assembly complexity and cost, enhances electrical connectivity, and provides a compact design suitable for high-voltage applications, including automobiles, with improved resistance to shock and vibration.
Implementation Method 1
the shielding connecting part comprises a plurality of elastic arms arranged around the second inserting hole
Implementation Method 2
the portion of the shielding layer surrounds the shielding connecting part; and the portion of the shielding layer of the cable is located between the plurality of elastic arms and the compress ring
Data Source
AI summary
The present invention discloses a terminal assembly with a cable and a connector assembly. The terminal assembly with the cable of the present invention has a terminal assembly including a connecting terminal, a shielding shell and an insulator arranged between the connecting terminal and the shielding shell; and a cable including a shielding layer. One portion of the shielding shell in the terminal assembly and one portion of the shielding layer in the cable form a mutual overlapping region along the radial direction of the cable. In the mutual overlapping region, the shielding layer is electrically connected with the shielding shell. The terminal assembly of the present invention is applicable to automobiles as a high-voltage connector. In its use in an automobile, the terminal assembly is capable of effectively resisting shock and preventing mechanical vibration from causing separation of the connector to affect safe use.