ELECTRICAL CABLE ASSEMBLY HAVING AN ELECTRICAL SHIELD

An electrical cable assembly includes an electrical cable extending a length from a first cable end to an opposite second cable end. The electrical cable includes at least one electrical wire. A first electrical connector is terminated to the first cable end of the electrical cable. A second electrical connector is terminated to the second cable end of the electrical cable. The assembly includes an electrical cable shield that includes a metallized fabric body that extends around the electrical cable along the length of the electrical cable. The metallized fabric body extends a length along the length of the electrical cable from a first shield end to a second shield end of the metallized fabric body. The first shield end of the metallized fabric body is dressed over the first electrical connector. The second shield end of the metallized fabric body is dressed over the second electrical connector.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to electrical cables, and more particularly to electrical shields for electrical cables.

Many electrical cables include electrical shields that provide electrical shielding for one or more electrical wires of the cable. Examples of known electrical cable shields include electrically conductive foils and braids of electrically conductive strands of material that surround the electrical wire(s) of the electrical cable. The shielding provided by electrical cable shields may reduce electromagnetic interference (EMI) emissions from the electrical cable or an assembly of the electrical cable and an electrical connector that terminates the electrical cable. Such EMI emissions may harm the signal integrity and/or electrical performance of neighboring electrical devices, for example. Moreover, government regulations may require that EMI emissions be contained to a predetermined level.

Known electrical cable shields are not without disadvantages. For example, it is difficult to install electrical cable shields after an electrical connector has been terminated to the electrical cable. Moreover, and for example, at least some known electrical cable shields may be inadequate because of the increasing signal speeds being transmitted through electrical cables and the electrical connectors terminated thereto. One example of a problem caused by such increasing signal speeds is that the assembly of an electrical cable and an electrical connector may leak EMI above certain signal speeds, such as above approximately 10 gigahertz (GHz), at the interface between the electrical cable shield and the electrical connector. For example, it may be difficult to terminate (i.e., electrically and/or mechanically connect) an electrically conductive foil to the electrical connector without tearing the foil. Electrically conductive foils thus may tend to leak EMI at the interface between the electrically conductive foil and the electrical connector. Moreover, and for example, while electrically conductive braids can be terminated to an electrical connector by being dressed over a ferrule of the electrical connector, such cable braids may be especially susceptible to EMI leakage at the interface between the cable braid and the ferrule because of the flare of the cable braid over the ferrule.

Accordingly, there is a need for an electrical cable shield that reduces EMI emissions.

BRIEF DESCRIPTION OF THE INVENTION

In an embodiment, an electrical cable assembly includes an electrical cable extending a length from a first cable end to an opposite second cable end. The electrical cable includes at least one electrical wire. A first electrical connector is terminated to the first cable end of the electrical cable. A second electrical connector is terminated to the second cable end of the electrical cable. The assembly includes an electrical cable shield that includes a metallized fabric body that extends around the electrical cable along the length of the electrical cable. The metallized fabric body extends a length along the length of the electrical cable from a first shield end to a second shield end of the metallized fabric body. The first shield end of the metallized fabric body is dressed over the first electrical connector. The second shield end of the metallized fabric body is dressed over the second electrical connector.

In an embodiment, an electrical cable assembly includes an electrical cable extending a length from a first cable end to an opposite second cable end. The electrical cable includes at least one electrical wire. The assembly includes an electrical cable shield having a metallized fabric body that extends around the electrical cable along the length of the electrical cable between the first and second cable ends. The metallized fabric body extends a length along the length of the electrical cable from a first shield end to a second shield end of the metallized fabric body. The metallized fabric body has opposite first and second edges that extend along the length of the metallized fabric body from the first shield end to the second shield end. The first and second edges are sewed together with an electrically conductive thread.

In an embodiment, an electrical cable assembly includes an electrical cable extending a length from a first cable end to an opposite second cable end. The electrical cable includes at least one electrical wire. The assembly includes an electrical cable shield having a metallized fabric body that extends around the electrical cable along the length of the electrical cable from the first cable end to the second cable end.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is a perspective view illustrating an embodiment of an electrical cable assembly10. The assembly10includes an electrical cable12, an electrical connector14terminated to the electrical cable12, and another electrical connector16terminated to the electrical cable12. The electrical cable12extends a length from an end18to an opposite end20. The ends18and20of the cable are also shown inFIG. 2. As can be seen inFIG. 1, the electrical connector14is terminated (i.e., electrically and mechanically connected) to the end18of the electrical cable12, while the electrical connector16is terminated to the end20of the electrical cable12. Accordingly, the electrical cable12extends between, and interconnects, the electrical connectors14and16. Each of the electrical connectors14and16may be referred to herein as a “first” and/or a “second” electrical connector. Each of the ends18and20of the electrical cable12may be referred to herein as a “first cable” end and/or a “second cable” end.

The electrical cable assembly10includes an electrical cable shield22that extends around the electrical cable12. A portion of the electrical cable shield22has been broken away fromFIG. 1to illustrate the underlying electrical cable12. As will be described in more detail below, the electrical cable shield22includes a metallized fabric body24for reducing EMI emissions from the assembly10.

FIG. 2is a perspective view of a portion of the electrical cable assembly10. Specifically, the electrical cable shield22has been removed from the assembly10inFIG. 2to better illustrate the electrical cable12and the electrical connectors14and16. The electrical cable12includes one or more electrical wires26. Each electrical wire26includes one or more electrical conductors28. Optionally, each electrical wire26is individually insulated and/or individually shielded. Moreover, each electrical conductor28of each electrical wire26is optionally individually insulated and/or individually shielded.

The electrical cable12may include any number of the electrical wires26, and each electrical wire26may include any number of electrical conductors28. In the illustrated embodiment, each electrical wire26is a twin axial wire having two signal conductors28contained within a common jacket30. The signal conductors28convey differential signals and are shielded (e.g., individually or with an electrically conductive shield, not shown, of the corresponding electrical wire26). Other types of electrical wires26may be provided in other embodiments. For example, the electrical wires26may be coaxial wires having a single signal conductor28therein.

Optionally, the electrical cable12includes an electrically insulative jacket (not shown) that extends around the electrical wires26. Moreover, the electrical cable12optionally includes an electrically conductive shield (not shown, and which may be referred to herein as a “second” electrical cable shield) that extends around the electrical wires26between the electrically insulative jacket and the electrical wires26. Examples of such an electrically conductive shield that extends around the electrical wires26between the electrically insulative jacket and the electrical wires26include a conventional electrically conductive foil and a conventional electrically conducive braid.

The electrical connectors14and16may each be any type of electrical connector. In the illustrated embodiment, the electrical connectors14and16are STRADA Whisper header connectors, commercially available from TE Connectivity, Harrisburg, Pa. In an embodiment, the electrical connector14and/or16is a high speed differential pair cable connector that includes a plurality of differential pairs of conductors mated at a common mating interface. The differential conductors may be shielded along the signal paths thereof to reduce noise, crosstalk, and/or other interference along the signal paths of the differential pairs. For example, in the illustrated embodiment, the electrical connector14includes a housing32that holds a plurality of contact modules34. The housing32includes a base wall36and shroud walls38extending from the base wall36to define a mating cavity40configured to receive a complementary mating connector (not shown) with which the electrical connector14is configured to mate. The shroud walls38guide mating of the electrical connector14with the complementary mating connector.

Each of the contact modules34includes a plurality of cable assemblies42held by a support body44. Each cable assembly42includes a pair of signal contacts46terminated to corresponding signal conductors28of the corresponding electrical wire26. Each cable assembly42also includes a ground shield48providing shielding for the signal contacts46. In the illustrated embodiment, the ground shield48peripherally surrounds the signal contacts46along the entire length of the signal contacts46to ensure that the signal paths are electrically shielded.

The support body44provides support for the cable assemblies42. The electrical wires26extend into the support body44such that the support body44supports a portion of the electrical wires26. The support body44may provide strain relief for the electrical wires26. Optionally, the support body44may be fabricated from a plastic and/or other dielectric material. In addition or alternatively, the support body44may be fabricated from one or more metal materials. At least a portion of the support body44is optionally electrically conductive to provide electrical shielding for the electrical wires26and/or the signal contacts46. For example, a majority or an approximate entirety of the support body44may be fabricated from one or more metal material to provide such electrical shielding. In other embodiments, the support body44may be a metalized dielectric material (e.g., a dielectric material plated or otherwise coated with a metal material, a dielectric material filled with a metal material, and/or the like) to provide electrical shielding for the electrical wires26and/or signal contacts46. In an embodiment, the support body44includes a metal plate (not shown) that is electrically connected to each ground shield48(to electrically common each ground shield48) and is surrounded by a dielectric material (e.g., an overmold and/or the like).

As can be seen inFIG. 2, multiple contact modules34are loaded into the housing32. The support bodies44of the contact modules34define a backshell50of the electrical connector14. In the illustrated embodiment, the housing32holds the contact modules34in parallel such that the cable assemblies42are aligned in columns. Any number of contact modules34may be held by the housing32depending on the particular application. When the contact modules34are stacked in the housing32, the cable assemblies42may also be aligned in rows. The backshell50may be referred to herein as a “first” and/or a “second” backshell.

Optionally, the electrical connectors14and16are substantially identical to one another. In the illustrated embodiment, the electrical connector16is substantially identical to the electrical connector14. Specifically, the electrical connector16includes a housing52that holds a plurality of contact modules54. The housing52includes a mating cavity60that is configured to receive a complementary mating connector (not shown) with which the electrical connector16is configured to mate.

Each of the contact modules54includes a plurality of cable assemblies62held by a support body64. Each cable assembly62includes a pair of signal contacts (not shown) terminated to corresponding signal conductors28of the corresponding electrical wire26. Each cable assembly62also includes a ground shield68providing shielding for the signal contacts. In the illustrated embodiment, the ground shield68peripherally surrounds the signal contacts along the entire length of the signal contacts to ensure that the signal paths are electrically shielded.

The support body64provides support for the cable assemblies62. The electrical wires26extend into the support body64such that the support body64supports a portion of the electrical wires26. The support body64may provide strain relief for the electrical wires26. Optionally, the support body64may be fabricated from a plastic and/or other dielectric material. In addition or alternatively, the support body64may be fabricated from one or more metal materials. At least a portion of the support body64is optionally electrically conductive to provide electrical shielding for the electrical wires26and/or the signal contacts. For example, a majority or an approximate entirety of the support body64may be fabricated from one or more metal material to provide such electrical shielding. In other embodiments, the support body64may be a metalized dielectric material (e.g., a dielectric material plated or otherwise coated with a metal material, a dielectric material filled with a metal material, and/or the like) to provide electrical shielding for the electrical wires26and/or signal contacts. In an embodiment, the support body64includes a metal plate (not shown) that is electrically connected to each ground shield68(to electrically common each ground shield68) and surrounded by a dielectric material (e.g., an overmold and/or the like).

The support bodies64of the contact modules54define a backshell70of the electrical connector16. In the illustrated embodiment, the housing52holds the contact modules54in parallel such that the cable assemblies62are aligned in columns. Any number of contact modules54may be held by the housing52depending on the particular application. When the contact modules54are stacked in the housing52, the cable assemblies62may also be aligned in rows. The backshell70may be referred to herein as a “first” and/or a “second” backshell.

FIG. 3is a perspective view of an embodiment of the electrical cable shield22. The electrical cable shield22includes the metallized fabric body24. The metallized fabric body24extends a length L from an end80to an opposite end82. The metallized fabric body24extends a width W from an edge84to an opposite edge86. As can be seen inFIG. 3, the edges84and86extend along the length L of the metallized fabric body24from the end80to the end82of the metallized fabric body24. Each of the ends80and82may be referred to herein as a “first shield end” and/or a “second shield end”. Each of the edges84and86may be referred to herein as a “first edge” and/or a “second edge”.

The metallized fabric body24of the electrical cable shield22is shown inFIG. 3in an unwrapped configuration. As will be described below, the metallized fabric body24is configured to be wrapped around the electrical cable12such that the length L of the metallized fabric body24extends along the length of the electrical cable12. The edges84and86of the metallized fabric body24can be connected together or overlapped such that the metallized fabric body24extends around the entirety of the circumference of the electrical cable12.

The metallized fabric body24includes a structure having at least one layer100of fabric and at least one layer102of metal. The metallized fabric body24may include any number of layers100and102overall, and may include any number of fabric layers100and any number of metal layers102. In the illustrated embodiment, the metallized fabric body24includes a single fabric layer100and a single metal layer102. The fabric layer100includes opposite sides104and106. The metal layer102extends on the side106of the fabric layer100. The metallized fabric body24may include one or more other layers (not shown) in addition to the fabric layer(s)100and the metal layer(s)102.

The fabric layer(s)100and the metal layer(s)102of the metallized fabric body24may be arranged relative to each other in any relative arrangement. In the illustrated embodiment, the fabric layer100defines an interior side108of the metallized fabric body24, while the metal layer102defines an exterior side110of the metallized fabric body24. Specifically, the side104of the fabric layer100defines the interior side108, and a side112of the metal layer102defines the exterior side110of the metallized fabric body24. The interior side108of the metallized fabric body24is configured to face the electrical cable12(FIGS. 1,2, and4) when the electrical cable shield22is installed over the electrical cable12. The exterior side110of the metallized fabric body24is configured to face away from the electrical cable12when the electrical cable shield22is installed over the electrical cable12.

As discussed above, the metallized fabric body24is not limited to the illustrated arrangement and number of the fabric and metal layers100102, respectively. For example, in some other embodiments, the fabric layer100defines the exterior side110of the metallized fabric body24and the metal layer102defines the interior side108of the metallized fabric body24. In another embodiment, the metallized fabric body24includes two fabric layers100(that define the interior side108and the exterior side110) and one or more metal layers102sandwiched between the two fabric layers100. Another embodiment of the metallized fabric body24includes two metal layers102(that define the interior side108and the exterior side110) and one or more fabric layers100sandwiched between the two metal layers102. In yet another embodiment, the metallized fabric body24includes an alternating pattern of fabric layers100and metal layers102. In still other embodiments, the metallized fabric body24includes one or more other layers (not shown) in addition to the fabric layer(s)100and the metal layer(s)102. For example, the metallized fabric body24may include one or more electrically insulative layers (not shown) that defines the exterior side110of the metallized fabric body24(e.g., extends over the outermost layer100or102), for example to prevent electrical shorting and/or to electrically insulate the exterior side110. Moreover, and for example, the metallized fabric body24may include one or more electrically insulative layers (not shown) that defines the interior side108of the metallized fabric body24(e.g., extends over the innermost layer100or102), for example to prevent electrical shorting. Another example includes providing the metallized fabric body24with one or more aesthetic and/or tactile (e.g., decorative, textured, and/or the like) layers that defines the exterior side110of the body24, for example to facilitate improving the look and/or feel of the electrical cable12.

The number and/or arrangement of the metal layer(s)102, the fabric layer(s)100, and the other layer(s) of the metallized fabric body24may be selected to: (1) provide a predetermined amount of electrical shielding; and/or (2) enable one or more metal layers102to electrically connect to the electrical connectors12and/or14(FIGS. 1,2, and4).

Each fabric layer100of the metallized fabric body24may be fabricated from any fabric, such as, but not limited to, nylon, polyester, cotton, wool, a natural fiber, a synthetic fiber, and/or the like. Each metal layer102of the metallized fabric body24may be fabricated from any metal, such as, but not limited to, aluminum, steel, tin, nickel, silver, gold, copper, a metal alloy, and/or the like. The materials used to fabricate the fabric layer(s)100and/or the metal layer(s)102of the metallized fabric body24may be selected to provide the metallized fabric body24with a predetermined flexibility. The materials used to fabricate the metal layer(s)102of the metallized fabric body24may be selected to enable the metallized fabric body24to provide a predetermined amount of electrical shielding and/or to provide the metallized fabric body24with a predetermined electrical conductivity. In an embodiment, the metallized fabric body24is woven or non-woven Flectron™ metalized fabric, which is commercially available from Laird Technologies.

FIG. 4is another perspective view of the electrical cable assembly10illustrating the electrical cable shield22installed over the electrical cable12. The metallized fabric body24has been wrapped around the electrical cable12such that the length L (FIG. 3) of the metallized fabric body24extends along the length of the electrical cable12. The metallized fabric body24extends around the circumference of the electrical cable12along at least a portion of the length of the electrical cable12. The metallized fabric body24may be wrapped around the electrical cable12relatively loosely such that there is an air gap between the interior side108of the metallized fabric body24and the electrical cable12along at least a portion of the length of the electrical cable12. Such an optional air gap can be seen inFIG. 1. In embodiments wherein the electrical cable12includes an electrically insulative jacket (not shown) that extends around the electrical wires26(FIG. 2) (and/or optionally an electrically conductive shield that extends around the electrical wires26between the electrically insulative jacket and the electrical wires26), the metallized fabric body24extends around the electrically insulative jacket and/or the electrically conductive shield.

In the illustrated embodiment, the edges84and86of the metallized fabric body24have been connected together such that the metallized fabric body24extends around the entirety of the circumference of the electrical cable12along at least a portion of the length of the electrical cable12. The edges84and86may be connected together using any suitable method, means, structure, and/or the like to hold the metallized fabric body24in the position wrapped around the electrical cable12, such as, but not limited to, an adhesive, by sewing the edges84and86together, a zip tie, a band, a rubber band, a heat recoverable ring, a clamp, a hose clamp, safety wire, and/or the like. In the illustrated embodiment, the edges84and86are sewn together using a thread88to connect the edges together. The edges84and86may be sewn together using any type of thread88, such as, but not limited to, a non-electrically conductive thread, an electrically conductive thread, and/or the like. Sewing the edges84and86together using an electrically conductive thread88may facilitate containing EMI emissions from leaking through a seam90of the electrical cable shield22. In alternative to being connected together at the edges84and86, the edges84and86may be overlapped by any amount to form any whole or partial number of layers of wrappings around the electrical cable12. The edges84and86may be held as overlapped using any suitable method, means, structure, and/or the like, such as, but not limited to, an adhesive, by sewing portions of the metallized fabric together with an electrically conductive or non-electrically conductive thread (e.g., the thread88), a zip tie, a band, a rubber band, a heat recoverable ring, a clamp, a hose clamp, safety wire, and/or the like.

The metallized fabric body24of the electrical cable shield22may extend around the electrical cable12along any amount and any portion(s) of the length of the electrical cable12. In the illustrated embodiment, the metallized fabric body24extends around the circumference of the electrical cable12along an approximate entirety of the length of the electrical cable12from the electrical connector14to the electrical connector16. Optionally, the end80of the metallized fabric body24is dressed over the electrical connector14. The opposite end82of metallized fabric body24is optionally dressed over the electrical connector16. Specifically, in the illustrated embodiment, the end80of the metallized fabric body24is dressed over the backshell50of the electrical connector14, and the end82is dressed over the backshell70of the electrical connector16. As can be seen inFIG. 4, the backshells50and70include fittings having non-circular profiles in the illustrated embodiment. Accordingly, in the illustrated embodiment, the ends80and82of the metallized fabric body24are dressed over the non-circular profiles of the backshells50and70, respectively. But, the ends80and82of the metallized fabric body24may each be dressed over a fitting of an electrical connector having any other shape.

Each of the ends80and82of the metallized fabric body24may be held on (i.e., as dressed over) the backshells50and70, respectively, using any suitable method, means, structure, and/or the like, such as, but not limited to, an adhesive, a zip tie, a band, a rubber band, a heat recoverable ring, a clamp, a hose clamp, safety wire, and/or the like. In the illustrated embodiment, the ends80and82are held on the respective backshells50and70using zip ties92and94, respectively.

Optionally, the end80and/or82of the metallized fabric body24is electrically connected to the respective electrical connector14and/or16. Specifically, the end80and/or the end82may be dressed over the respective backshell50and/or70such that the end80and/or82is electrically connected to the optional electrical shield provided by the support bodies44and/or64of the respective backshell50and/or70. The metallized fabric body24may thereby form part of a ground and/or shielding circuit of the electrical cable assembly10. The ends80and82may each be electrically connected to the respective electrical connector14and16using any suitable method, means, structure, and/or engagement. For example, the interior side108of the metallized fabric body24may engage in physical contact with an exterior surface of the backshell50and/or70that defines an electrically conductive portion of the backshell50and/or70.

As should be apparent fromFIGS. 1-4, the metallized fabric body24may be installed around the electrical cable12after the electrical connectors14and/or16have been terminated to the electrical cable12. The electrical cable shield22may therefore be more easily installed to the electrical cable12(and optionally on the electrical connectors14and16) than at least some known electrical cable shields.

When installed on the electrical cable12and the electrical connectors14and16as shown inFIGS. 1 and 4, the electrical cable shield22is configured to provide electrical shielding along the length of the electrical cable12(and optionally along the backshells50and/or70) that facilitates reducing EMI emissions from the electrical cable assembly10.

The embodiments described and/or illustrated herein may provide an electrical cable shield that reduces EMI emissions from an electrical cable assembly. For example, the embodiments described and/or illustrated herein may provide an electrical cable shield that reduces EMI emissions from leaking through an interface between the electrical cable shield and an electrical connector that terminates the electrical cable.