Patent Application
20220190538
The disclosure relates to a barrel crimp retention feature for a connector used with a shield, such as braided wire.
Cables such as those used in high voltage applications or coaxial cables for video typically include a braided shield to prevent interference. Customer demands to meet stringent automotive-grade cable retention requirements is challenging with typical stamped and formed shielded crimp wing designs. That is, the electrical connector may pull away from the shield under design loads. Current cable designs include formed crimped wing geometries that depend upon sustainable compression forces to provide consistent friction forces throughout cable usage. New customer space constraints demand cable designs with thinner materials, making cable design even more challenging.
In one exemplary embodiment, a cable assembly includes coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The cable assembly further includes a cable that has at least one wire surrounded by an inner insulator that is covered in a metallic shield. The metallic shield is arranged in between the inner and outer barrels. The inner barrel includes a retention feature that is arranged beneath the metallic shield. The retention feature protrudes radially outward from the inner barrel to an outermost diameter. The outer barrel includes a crimped portion that is arranged adjacent to the retention feature and has an innermost diameter that is less than the outermost diameter to capture the metallic shield therebetween and prevent the outer barrel from axial movement relative to the inner barrel.
In a further embodiment of any of the above, the metallic shield is provided by a braided or foil sleeve.
In a further embodiment of any of the above, the inner barrel is secured to an electrical connector that has an outer housing. The metallic shield is grounded and secured to the outer housing.
In a further embodiment of any of the above, the metallic shield is covered in a nonconductive sheathing. The outer barrel is secured over the nonconductive sheathing.
In a further embodiment of any of the above, the inner and outer barrels are each metallic cylindrically-shaped or oval shaped members.
In a further embodiment of any of the above, the retention feature is provided by a flange at a terminal end of the inner barrel that is flared radially outward.
In a further embodiment of any of the above, the outer barrel has a window and the retention feature is arranged within the window. The flange is provided about a circumference of the terminal end. The flange is axially aligned with the window.
In a further embodiment of any of the above, the outer barrel has a window and the retention feature is arranged within the window. The retention feature is provided by a protrusion in the inner barrel that is arranged axially inboard of a terminal end. The protrusion is axially and circumferentially aligned with the window.
In a further embodiment of any of the above, the crimped portion is a plastically deformed area of the outer barrel that generates a clamping force on the metallic shield and the inner barrel.
In another exemplary embodiment, a method of assembling a cable includes the steps of: a) inserting the cable into an outer barrel, b) inserting an end of an inner barrel underneath a metallic shield, c) positioning a retention feature on the inner barrel, the retention feature protrudes radially outward from the inner barrel, and d) crimping the outer barrel to capture the metallic shield between the inner and outer barrels and prevent relative axial movement of the inner and outer barrels.
In a further embodiment of any of the above, step d) includes crimping the outer barrel adjacent to a window in the outer barrel. The retention feature is in the window.
In a further embodiment of any of the above, the cable includes at least one wire that is surrounded by an inner insulator that is covered in the metallic shield. Step b) includes inserting the end of the inner barrel between the inner insulator and the metallic shield.
In a further embodiment of any of the above, step c) includes sliding the outer barrel axially over the inner barrel and the metallic shield.
In a further embodiment of any of the above, prior to performing step a), the method includes a step of al) forming the retention feature by bending a circumferential flange radially outward on a terminal end of an inner barrel blank.
In a further embodiment of any of the above, prior to performing step a), the method includes a step of al) forming the retention feature by deforming a protrusion axially inboard of a terminal end of an inner barrel blank.
In a further embodiment of any of the above, the retention feature is provided by a protrusion in the inner barrel that is arranged axially inboard of the terminal end. Step c) includes circumferentially aligning the protrusion with the window.
In a further embodiment of any of the above, the method includes step e) securing the inner barrel to a terminal connector that has an outer housing. The metallic shield is grounded to the outer housing.
In a further embodiment of any of the above, the cable includes a nonconductive sheathing that covers the metallic shield. The outer barrel is secured over the nonconductive sheathing.
In a further embodiment of any of the above, the method includes step f) arranging a nonconductive strain relief member over at least portions of the terminal connector, the outer barrel and the nonconductive sheathing.
In a further embodiment of any of the above, step d) includes plastically deforming a portion of the barrel to provide an innermost diameter that is less than an outermost diameter of the retention feature.
The disclosure can be further understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. Like reference numbers and designations in the various drawings indicate like elements.
A cable assembly is illustrated in
A connector 20 is provided at one end of the cable 12. Although the example connector 20 is illustrated as a female connector, the connector 20 may also be a male connector or a splice connector. The connector 20 includes an outer housing 22 that is grounded to the shield 18. An inner nonconductive housing 26 supports an electrical terminal 24 electrically connected to the wire 14. A nonconductive sheeting 28, such as a polymer material, is arranged over the shield 18.
Referring to
The inner and outer barrel blanks 40, 50 are respectively shown in
Referring to the outer barrel blank 50, a main body portion 52 is provided as a cylindrical or oval shape. The main body portion 52 is adjoined to a winged portion 58 by a longitudinal portion 56 which is arcuate in shape. The longitudinal portion is narrower than the main body portion 52 and the winged portion 58 such that a window portion 54 is provided that forms the window 38, best shown in
Referring to
Another example configuration is illustrated in
In operation, the cable assembly 10 is assembled by inserting the cable 12 into the outer barrel 34. An end of the inner barrel 32 is arranged underneath the shield 18. Because the retention feature 36 extends radially outward, the ease of insertion of the inner barrel 32 between the shield 18 and the inner insulator 16 is improved. The retention feature 36 is positioned within the window 38. The outer barrel 34 is crimped adjacent to the window 38 to capture the shield 18 between the inner and outer barrels 32, 34 and prevent relative axial movement of the inner and outer barrels 32, 34, thus, securely retaining the shield 18.
It should also be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit herefrom. Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.
Although the different examples have specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.
Although an example embodiment has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of the claims. For that reason, the following claims should be studied to determine their true scope and content.
