Systems and methods for electrical harness construction

Patent metadata

Field	Value
Publication number	US-9716374-B2
Application number	US-201414147391-A
Country	US
Kind code	B2
Filing date	Jan 3, 2014
Priority date	Jan 3, 2014
Publication date	Jul 25, 2017
Grant date	Jul 25, 2017

Abstract

Electrical harnesses and methods of manufacturing electrical harnesses are disclosed. The electrical harnesses may comprise an electrically conductive wire, an electrical connector in electrical communication with the conductive wire, a metal clad fiber (“MCF”) braided shield surrounding a portion of the electrically conductive wire, and an overbraid surrounding a portion of the MCF braided shield, wherein the electrical connector comprises an integrated backshell. Methods of making electrical harnesses may comprise connecting an electrical connector with a conductive wire, disposing a metal clad fiber (“MCF”) braided shield to at least partially surround the conductive wire; and disposing an overbraid to at least partially surround the MCF braided shield, wherein the electrical connector comprises an integrated backshell.

First claim

What is claimed is:

1. An electrical harness comprising:
an electrically conductive wire;
an electrical connector in electrical communication with the conductive wire;
a metal clad fiber (“MCF”) braided shield surrounding a portion of the electrically conductive wire, the MCF braided shield comprising a metal-clad fiber, the metal-clad fiber comprising a synthetic fiber clad in a metal; and
an overbraid surrounding a portion of the MCF braided shield,
a heatshrink material surrounding at least a portion of the overbraid,
wherein the electrical connector comprises an integrated metallic backshell comprising a boot seat and a separate land;
the MCF braided shield terminates on the separate land, the MCF braided shield perimetrically surrounding a radially outer surface of the separate land;
the MCF braided shield is secured directly to the integrated metallic backshell of the electrical connector;
the overbraid is secured directly to the electrical connector;
the heatshrink material comprises a heatshrink boot secured to the boot seat of the electrical connector, wherein the heatshrink boot perimetrically surrounds a radially outer surface of the boot seat;
the overbraid terminates on the boot seat, the overbraid perimetrically surrounding a radially outer surface of the boot seat; and
the overbraid axially extends beyond the MCF braided shield.

2. The electrical harness according to claim 1 , further comprising a fiberglass braided shield surrounding the portion of the electrically conductive wire.

3. The electrical harness according to claim 2 , wherein the fiberglass braided shield is surrounded by the MCF braided shield.

4. The electrical harness according to claim 2 , wherein the MCF braided shield comprises nickel plated stainless steel clad micro filaments.

5. The electrical harness according to claim 2 , wherein the electrically conductive wire forms part of a shielded jacketed cable.

6. The electrical harness according to claim 1 , wherein the electrical connector comprises at least one of a stainless steel shell, an aluminum shell, an aluminum lock ring, and a stainless steel lock ring.

7. The electrical harness according to claim 1 , wherein the MCF braided shield comprises aramid fibers.

8. The electrical harness according to claim 1 , wherein the overbraid comprises polyetheretherketone.

9. The electrical harness of claim 1 , wherein the overbraid comprises at least one of polyaryletherketone (PAEK), polytetraflouroethylene (PTFE), or polyetheretherketone (PEEK) tubular overbraids.

10. A method of making an electrical harness comprising:
connecting an electrical connector with a conductive wire,
wherein the electrical connector comprises an integrated metallic backshell comprising a boot seat and a separate land;
disposing a metal clad fiber (“MCF”) braided shield to at least partially surround the conductive wire wherein the MCF braided shield comprises a metal-clad fiber, the metal-clad fiber comprising a synthetic fiber clad in a metal;
disposing an overbraid to at least partially surround the MCF braided shield;
disposing a heatshrink material to surround at least a portion of the overbraid; and
disposing the MCF braided shield to at least partially surround a radially outer surface of the separate land,
wherein the MCF braided shield is secured directly to the integrated metallic backshell of the electrical connector;
the overbraid is secured directly to the electrical connector;
the heatshrink material comprises a heatshrink boot secured to the boot seat of the electrical connector, wherein the heatshrink boot perimetrically surrounds a radially outer surface of the boot seat;
the overbraid terminates on the boot seat, the overbraid perimetrically surrounding a radially outer surface of the boot seat; and
the overbraid axially extends beyond the MCF braided shield.

11. The method of making an electrical harness according to claim 10 , further comprising securing the overbraid directly to the electrical connector.

12. The method of making an electrical harness according to claim 10 , further comprising disposing a fiberglass braided shield to at least partially surround the conductive wire.

13. The electrical harness of claim 10 , wherein the heatshrink boot comprises a substantially straight heatshrink boot or an angled heatshrink boot.

Assignees

• Rohr Inc

Inventors

• Rohr Thomas
• Manning Douglas G
• Aitken William

Classifications

• H02G3/0406 Primary

  Details thereof (installation or suspension of conduit channels and other supports H02G3/263) · CPC title

• H01B13/01263

  Tying, wrapping, binding, lacing, strapping or sheathing harnesses · CPC title

• H01R43/01

  for connecting unstripped conductors to contact members having insulation cutting edges · CPC title

• H01R43/28 Primary

  for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26 · CPC title

• Y10T29/49174

  Assembling terminal to elongated conductor · CPC title