Threaded Shielding Termination Assembly for Bend-Radius EMI Constraints
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Solution Overview
Problem
Conventional electrical shielding termination systems face challenges in installation due to large bend radius issues with high amperage power feeders, particularly in vehicle applications, where shielding individual phases is not feasible due to weight concerns, and existing methods struggle with effective circumference connections for electromagnetic interference (EMI) protection.
Innovation Solution
A conductor shielding termination assembly comprising a conductive housing tube with threads, a non-conductive shoulder bushing, and a jam nut with threads that trap a shielding termination, along with a gasket for flexible compression and stress relief, allowing for a 360-degree connection and improved installation flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shielding is done at the harness bundle level for EMI protection, then EMI shielding effectiveness is improved, but the bundle bend radius becomes too large to facilitate installation
Solution Approach 1:
The shielding system is segmented into individual phase-level shielding components rather than requiring complete harness bundle shielding. Each phase conductor can be shielded independently with smaller bend radii, allowing installation in tight spaces while maintaining EMI protection where most needed.
Solution Approach 2:
Shielding is applied locally to individual high-amperage power feeder phases rather than uniformly across the entire harness bundle. This concentrates EMI protection where it is most critical (high-power conductors) while reducing overall bend radius requirements and improving installation flexibility.
2Object-affected harmful factors
If shielding of large gauge power feeders is done for EMI protection, then EMI shielding effectiveness is improved, but vehicle weight increases
Solution Approach 1:
Shielding is selectively applied only to large gauge power feeder phases that require EMI protection, rather than shielding the entire harness bundle including smaller conductors. This reduces the total amount of shielding material and overall weight while maintaining protection where most needed.
Solution Approach 2:
The shielding system is divided into separate phase-level components rather than a single heavy bundle-level shield. This allows selective shielding of only the high-amperage power feeders that require protection, reducing total shielding material and vehicle weight.
3Reliability
If conventional shielding terminations with internal cone clamping geometry or band clamps are used, then shielding connection is achieved, but repairability is limited (crimped band clamps are not repairable)
Solution Approach 1:
The termination system uses a dynamic, adjustable clamping mechanism with a clamp member that can be loosened and repositioned. This allows the shielding connection to be easily removed, reinstalled, or adjusted, providing full repairability while maintaining reliable electrical connection during operation.
Solution Approach 2:
A clamp member acts as an intermediary between the shielding braid and the housing, providing a mechanical and electrical connection that can be easily engaged and disengaged. This intermediate component enables repairability without compromising the reliability of the shielding connection during normal operation.
4Ease of operation
If threads are used for shielding termination connection, then ease of installation and repair is improved, but the threads may cut the shielding termination
Solution Approach 1:
A clamp member with a broad contact surface acts as an intermediary between the threaded housing and the shielding braid. This intermediate component distributes the clamping force over a larger area, preventing the threads from directly cutting or damaging the shielding termination while maintaining secure electrical connection.
Solution Approach 2:
The clamp member is designed with a compliant, flexible structure that can deform to accommodate the shielding braid without concentrating stress at sharp edges. This flexible interface protects the shielding termination from thread-induced damage while maintaining reliable connection.
Data Source
Figure 1A~1B
Figure 2~3
Figure 4A~4B
AI summary
A conductor shielding termination assembly can include a housing tube (101) defining an inner diameter housing channel therethrough and having housing threads on an outer diameter thereof. The housing tube (101) can be made of conductive material. The assembly can include a shoulder bushing (103) configured to insert within the inner diameter housing channel of the housing tube (101). The shoulder bushing (103) can define an inner diameter bushing channel sized to receive an unshielded portion of a conductor. The assembly can include a jam nut (107) comprising a nut inner diameter channel sized to receive a shielded portion of the conductor and nut threads on an inner diameter thereof configured to mesh with the housing threads. The jam nut (107) and housing tube (101) can be configured to trap a shielding termination within the meshed housing threads and jam nut threads (107b).