Development of a Connector for Carbon Fiber Screened Cables with Conductive Springs

Research is in progress to lighten cables for vessels by replacing shield layers with carbon fiber materials. Since there has been no actual case where carbon fiber is used as a shield material for cables, it is necessary, first of all, to secure the safety of this new material by examining the physical property, connecting modes of cable connectors and the contact resistance of carbon fiber. Carbon fiber has a difficulty in maintaining its shape thus special property is required when used for connections and an easy break-down due to characteristic binding post-tensioning force. So, a new type of screened cable connector needs to be developed, which overcomes carbon fiber's easy breaking or cutting and also minimizes contact resistance in connections. In this study, a conductive spring-applied and gland-type cable connector was designed and manufactured, followed by applicability evaluation through measurement of contact resistance of the cable. As for aluminum alloy connectors, the total weight was reduced as much as 60% in comparison with brass connectors, and the contact resistance was as high as that of non-connected solid cables. This study sheds light on new design technology for new connectors in cables typically used in heavy transportations.