Electricity: conductors and insulators – Conduits – cables or conductors – Combined
Reexamination Certificate
2000-03-15
2001-06-12
Reichard, Dean A. (Department: 2833)
Electricity: conductors and insulators
Conduits, cables or conductors
Combined
Reexamination Certificate
active
06246001
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing a grounding construction for a plurality of shielded cables, such as a plurality of shielded cables arranged in an automotive vehicle. The invention also relates to a grounding construction for a plurality of shielded cables, and particularly to a grounding construction to join a plurality of shielded cables and to connect the shielded cables to a ground wire without using a joint connector.
2. Description of the Related Art
A prior art shielded cable includes one or more core wires disposed in a braided metal wire tube. The braided wire tube then is covered with a sheath or insulation coating. The braided wire is provided for shielding, and hence needs to be grounded. Thus, as shown in FIGS.
4
(A) and
4
(B), end portions of sheaths
1
a
of prior art shielded cables
1
are stripped to expose the braided wires, and the exposed braided wires are formed into drain twisted wires
1
b
. Terminals
2
are mounted at the leading ends of the twisted wires
1
b
and are inserted into a joint connector
3
for connection with a joint terminal
4
in the joint connector
3
. A terminal at one end of a ground wire
5
is connected with the joint terminal
4
, and a terminal
6
at the other end of the ground wire
5
is grounded to a vehicle body panel or the like.
The sheath
1
a
is stripped at a position P where the leading end of the prior art shielded cable
1
is branched, as shown in FIG.
5
. For example, since the length of a branch wire
1
-
a
is 100 mm in the shielded cable
1
A, the length of a drain twisted wire
1
b
-
1
is 100 mm. Further, since the length of a branch wire
1
-
b
is 200 mm in a shielded cable
1
B, the length of a drain twisted wire
1
b
-
2
is 200 mm. Furthermore, since the length of a branch wire
1
-
c
is 300 mm in a shielded cable
1
C, the length of a drain twisted wire
1
b
-
3
is 300 mm. The terminals
2
are mounted at the leading ends of the drain twisted wires
1
b
-
1
to
1
b
-
3
for connection with the joint terminal
4
in the joint connector
3
. Tubes
7
are designed for insulation and protection, and are mounted on the twisted wires between the stripping positions P and connecting portions with the joint connector
3
.
If the joint connector is used to ground the metal fiber braided wires of the plurality of shielded cables, as described above, a large space is taken up. However, there generally is not much space remaining in the arrangement of shielded cables. Accordingly, it often is difficult to ensure a mount space for the joint connector. Further, the use of the joint connector leads to an increased number of parts, such as a joint terminal, a joint connector, and tubes. The use of the joint connector also leads to an increased number of operation steps including the mounting of the terminals and the connection of the connector. This increase in the number of parts and the more complicated assembly disadvantageously increases costs.
If the ends of the drain twisted wires and the end of the ground wire are welded together, the joint connector is unnecessary. Thus, a spatial problem can be solved, the number of parts can be reduced, and the number of operation steps can be reduced. However, as shown in
FIG. 6
, the drain twisted wires differ in length. Furthermore, the drain twisted wires have a low rigidity and are difficult to straighten. Therefore, the leading ends cannot be aligned easily, and it is impossible to apply local welding thereto at the present state.
In view of the above problems, an object of the present invention is to enable ends of drain wires of a plurality of shielded cables and an end of a ground wire to be locally end-processed, in particular connected or welded together, so that a joint connector can be dispensed with.
SUMMARY OF THE INVENTION
According to the invention, there is provided a method for manufacturing a grounding construction or arrangement for grounding a plurality of shielded cables by connecting shields of the plurality of shielded cables with each other and with a ground wire. The shields may be drain wires. The method may comprise stripping sheaths of the plurality of shielded cables at positions corresponding to a sheath stripping position for the longest shield. The method proceeds by bundling the shields with the ground wire by a bundling means from the sheath stripping positions. The method continues by locally applying an end processing to ends of the shields exposed from the leading end of the bundling means and to a core exposed from one end of the ground wire.
According to a preferred embodiment of the invention, the step of locally applying an end processing comprises a local application of resistance welding.
Preferably, in the stripping step a length between the sheath stripping positions and the local end processing position is about 150 mm. The method then may further comprise the step of cutting off leading end portions of the shields beyond this length. Additionally the bundling means employed in the bundling step is wound on a bundling length of about 130 mm to 135 mm from the sheath stripping positions so that the shields and the core of the ground wire substantially project from the leading end of the bundling means by about 15 mm to 20 mm. End processing then is applied to this projecting portion of the wire bundle.
The method may further comprise a step of mounting a cap, preferably made of an insulating resin, on the locally end processed wire ends.
Most preferably, the mounting step comprises a step of fixing a tongue projecting from an insertion opening of the cap to the bundle of the shields and the ground wire by a fixing means, preferably a tape.
According to the invention, there is further provided a grounding construction or arrangement for grounding a plurality of shielded cables by connecting shields, in particular drain wires of the plurality of shielded cables with each other and with a ground wire. The shields may be drain wires of the plurality of shielded cables. Ends of the shields exposed from the plurality of shielded cables and a core exposed from one end of the ground wire are locally end-processed to form a locally end-processed portion. The locally end-processed portion is adjacent an end-processing position that is spaced by a predetermined bundling length from a stripping position. The stripping position is the position to which the shields are exposed by stripping sheaths of the plurality of shielded cables and corresponds to a sheath stripping position for the longest shield. The shields are bundled with the ground wire by a bundling means over the bundling distance.
According to a preferred embodiment, the shields comprise drain twisted wires preferably made of metal fiber braided wires and/or a conductive film or layer.
Preferably, a length between the sheath stripping positions and the local end processing position is about 150 mm. Leading end portions of the shields beyond this length are cut off, and the bundling means is wound on a bundling length of about 130 mm to 135 mm from the sheath stripping positions. Thus the shields and the core of the ground wire substantially project from the leading end of the bundling means by about 15 mm to 20 mm, and this projecting portion of the wire bundle is end-processed. The bundling means preferably comprises a tape.
A cap made of an insulating resin, may be mounted on the locally end processed wire ends. A tongue may project from an insertion opening of the cap preferably and may be fixed to the bundle of the shields and the ground wire by a fixing means, preferably a tape.
According to a further preferred embodiment of the invention, there is provided a grounding construction for grounding a plurality of shielded cables by connecting drain twisted wires made of metal fiber braided wires of the plurality of shielded cables with each other and with a ground wire. Sheaths of the plurality of shielded cables are stripped at positions corresponding to a sheath stripping position for
Casella Anthony J.
Hespos Gerald E.
Nguyen Chau N.
Porco Michael J.
Reichard Dean A.
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