Device and method for splicing shielded wire cables

Patent metadata

Field	Value
Publication number	US-9906003-B1
Application number	US-201715436894-A
Country	US
Kind code	B1
Filing date	Feb 20, 2017
Priority date	Dec 12, 2016
Publication date	Feb 27, 2018
Grant date	Feb 27, 2018

Abstract

A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables that are spliced together is presented. The assembly includes a splicing device having a generally planar bus bar formed of a conductive material, wherein the exposed core conductors of the shielded wire cables are welded to the bus bar, thereby electrically interconnecting the exposed core conductors. A conductive sleeve encloses bus bar and interconnects the shield conductors of the shielded wire cables, providing shielding for the exposed core conductors and continuity for the shield conductors. An outer insulator enclosing the conductive sleeve. A method of splicing shielded wire cables using such a device is also presented herein.

First claim

We claim:

1. A wire harness assembly, comprising:
a first shielded wire cable having a first exposed shield conductor and a first exposed core conductor;
a second shielded wire cable having a second exposed shield conductor and a second exposed core conductor;
a third shielded wire cable having a third exposed shield conductor and a third exposed core conductor;
a fourth shielded wire cable having a fourth exposed shield conductor and a fourth exposed core conductor;
a generally planar bus bar formed of a conductive material, wherein the first, second, third, and fourth exposed core conductors are welded to the bus bar, thereby electrically connecting the first, second, third, and fourth exposed core conductors;
a conductive sleeve enclosing a portion of the first, second, third, and fourth exposed shield conductors;
an inner insulator enclosing the bus bar and disposed within the conductive sleeve; and
an outer insulator enclosing the conductive sleeve.

2. The wire harness assembly according to claim 1 , wherein the bus bar defines a closed ended longitudinal slot extending therethrough and wherein the inner insulator includes a post having a bottom portion attached to the inner insulator and a top portion extending through the longitudinal slot.

3. The wire harness assembly according to claim 2 , wherein the post is moveable within the longitudinal slot.

4. The wire harness assembly according to claim 2 , wherein the post is formed of a thermoplastic material and wherein the top portion of the post is thermally deformed to stake the bus bar to the inner insulator.

5. The wire harness assembly according to claim 4 , wherein an interference fit exists between the thermally deformed top portion of the post and the bus bar, thereby inhibiting movement of the post within the longitudinal slot.

6. The wire harness assembly according to claim 5 , wherein the post and the inner insulator are integrally formed of the same thermoplastic material.

7. A method of splicing shielded wire cables together, comprising the steps of:
providing a first shielded wire cable having a first exposed shield conductor and a first exposed core conductor;
providing a second shielded wire cable having a second exposed shield conductor and a second exposed core conductor;
providing a third shielded wire cable having a third exposed shield conductor and a third exposed core conductor;
providing a fourth shielded wire cable having a fourth exposed shield conductor and a fourth exposed core conductor;
providing a first, second, third, and fourth ferrule;
attaching the first, second, third, and fourth ferrules to the first, second, third, and fourth shield conductors respectively;
providing a generally planar bus bar formed of a conductive material;
providing a conductive sleeve;
providing an inner insulator formed of a thermoplastic material;
disposing the bus bar within the inner insulator;
aligning the first, second, third, and fourth ferrules with the bus bar;
welding the first, second third, and fourth exposed core conductors to the bus bar, thereby electrically connecting the first, second third, and fourth exposed core conductors;
aligning the first, second, third, and fourth ferrules relative to the inner insulator;
disposing the inner insulator and the first, second, third, and fourth exposed shield conductors within the conductive sleeve;
attaching the first, second, third, and fourth ferrules to the conductive sleeve, thereby providing a conductive path between the first, second, third, and fourth exposed shield conductors;
providing an outer insulator formed of a nonconductive material; and
disposing the conductive sleeve within the outer insulator.

8. The method according to claim 7 , wherein the bus bar defines a closed ended longitudinal slot extending therethrough and the inner insulator includes a post having a bottom portion attached to the inner insulator and a top portion configured to extend through the longitudinal slot, wherein the step of disposing the bus bar within the inner insulator includes the sub-step of disposing the post within the longitudinal slot and wherein the method further comprises the step of thermally deforming the top portion of the post to provide an interference fit between the post and the bus bar, thereby inhibiting movement of the post within the longitudinal slot.

9. The method according to claim 8 , wherein the post and the inner insulator are integrally formed of the same thermoplastic material.

10. A wire harness assembly having a spliced joint formed by a method comprising the steps of:
providing a first shielded wire cable having a first exposed shield conductor and a first exposed core conductor;
providing a second shielded wire cable having a second exposed shield conductor and a second exposed core conductor;
providing a third shielded wire cable having a third exposed shield conductor and a third exposed core conductor;
providing a fourth shielded wire cable having a fourth exposed shield conductor and a fourth exposed core conductor;
providing a first, second, third, and fourth ferrule;
attaching the first, second, third, and fourth ferrules to the first, second, third, and fourth shield conductors respectively;
providing a generally planar bus bar formed of a conductive material;
providing a conductive sleeve;
providing an inner insulator formed of a thermoplastic material;
disposing the bus bar within the inner insulator;
aligning the first, second, third, and fourth ferrules with the bus bar;
welding the first, second third, and fourth exposed core conductors to the bus bar, thereby electrically connecting the first, second third, and fourth exposed core conductors;
aligning the first, second, third, and fourth ferrules relative to the inner insulator;
disposing the inner insulator and the first, second, third, and fourth exposed shield conductors within the conductive sleeve;
attaching the first, second, third, and fourth ferrules to the conductive sleeve, thereby providing a conductive path between the first, second, third, and fourth exposed shield conductors;
providing an outer insulator formed of a nonconductive material; and
disposing the conductive sleeve within the outer insulator.

11. The wire harness assembly according to claim 10 , wherein the bus bar defines a closed ended longitudinal slot extending therethrough and the inner insulator includes a post having a bottom portion attached to the inner insulator and a top portion configured to extend through the longitudinal slot, wherein the step of disposing the bus bar within the inner insulator includes the sub-step of disposing the post within the longitudinal slot and wherein the method further comprises the step of thermally deforming the top portion of the post to provide an interference fit between the post and the bus bar, thereby inhibiting movement of the post within the longitudinal slot.

12. The wire harness assembly according to claim 11 , wherein the post and the inner insulator are integrally formed of the same thermoplastic material.

Assignees

• Delphi Tech Inc
• Delphi Techologies Inc

Inventors

• Volpone Thomas A
• Iler Troy A

Classifications

• H02G15/18

  protected by sleeves, e.g. for communication cable (two-part covers H02G15/10 {; preforms having internal stresses B29C61/00}) · CPC title

• H05K9/0098

  for shielding electrical cables · CPC title

• H01B7/0045

  Cable-harnesses · CPC title

• H01B5/02

  Single bars, rods, wires, or strips · CPC title

• H01B13/01209

  Details · CPC title