Electromagnetic interference resistant circuit connection bus

Abstract

The utility model provides a kind of circuit connection bus of anti-electromagnetic interference, including line body, end, seat head, end sleeve, the end of line body is fixedly connected with end head.The utility model has the advantages that: the conductive shielding layer inside line body is carefully peeled off and firmly welded, crimped or clamped to the conductive area specially designed in end head, i.e. conductive insert.The external interference electromagnetic field is absorbed / reflected by the conductive shielding layer in line body.The interference current absorbed by shielding layer is conducted to the connecting point inside end head.The interference current is passed through the metallization / conductive long-hole area of end head.Clever use of long-hole as key grounding point: the long-hole of end head originally only used for heat dissipation, weight reduction or positioning is innovatively transformed into the start point of shielding layer lead-out end and grounding path, and is given new function.This is a clever reuse in structure.A clear and continuous internal anti-electromagnetic interference path (shielding layer->end head connection->long-hole) is designed.The shielding effect is ensured.

Description

Technical Field

[0001] This utility model relates to the field of circuit bus technology, and in particular to a circuit connection bus that is resistant to electromagnetic interference. Background Technology

[0002] In the field of electrical and electronic equipment, circuit connection buses (such as power lines and signal harnesses) are key components for energy transmission and signal delivery. However, with the increasing integration of electronic devices, the widespread use of switching power supplies, and the rising operating frequencies, the electromagnetic environment has become more complex, and electromagnetic interference (EMI) problems have become increasingly prominent. Electromagnetic noise inside the equipment and interference sources in the external environment (such as lightning, nearby devices, and wireless signals) can easily couple onto the connection bus. This coupled interference can not only be conducted along the bus into the equipment, disrupting the normal operation of sensitive circuits, leading to signal distortion, increased bit error rate, or even system collapse, but it can also radiate noise outward through the bus, causing the equipment to fail to meet increasingly stringent electromagnetic compatibility (EMC) regulations.

[0003] In existing technologies, a common method to improve the electromagnetic interference immunity of connection buses is to add a conductive shielding layer (such as a metal braided mesh or aluminum foil) outside the insulation layer of the bus (wire). Theoretically, this shielding layer can absorb or reflect external interference or prevent internal signal noise leakage. However, in practical applications, this shielding design has significant limitations and shortcomings, especially regarding the reliable grounding of the shielding layer:

[0004] Inconvenient or unreliable grounding: The shielding layer typically needs to be connected to the device's metal housing or a common ground at the end of the bus to form a low-impedance path to conduct interference current away ("conduction" rather than "blocking" is key to shielding). Traditional methods rely on additional clips, soldered terminals, or directly pressing the shielding layer into the connector's metal housing. These methods are complex to operate, may increase assembly steps and costs, and in harsh environments (such as vibration, high and low temperature changes), the connection points are prone to loosening and oxidation, leading to grounding failure and weakening or even completely losing the shielding effect.

[0005] Discontinuous grounding path or excessively high impedance: For the plastic housing portion of a connector (such as the terminal), conventional shielding layers struggle to achieve a reliable and low-impedance connection. If the shielding layer only connects to the metal component at the connector entrance, while the area in front of it (near the plug interface) remains a large unshielded area made of plastic, the interference current collected by the shielding layer must travel a long path to reach the final grounding point. This effectively increases the impedance and inductance of the grounding loop, leading to poor grounding at high frequencies and preventing interference energy from being effectively conducted away. Furthermore, plastic itself is not conductive and cannot serve as part of the grounding path. Therefore, an electromagnetic interference-resistant circuit connection bus is proposed to address these issues. Utility Model Content

[0006] The purpose of this invention is to at least solve one of the aforementioned technical defects.

[0007] Therefore, one objective of this utility model is to propose an electromagnetic interference-resistant circuit connection bus to solve the problems mentioned in the background art and overcome the shortcomings of the prior art.

[0008] To achieve the above objectives, one embodiment of the present invention provides an electromagnetic interference-resistant circuit connection bus, including a wire body, a terminal, a connector, and a sleeve. The terminal is fixedly connected to the end of the wire body, the connector is fixedly connected to the end of the terminal, and the sleeve is fixedly connected to the end of the connector. The sleeve is hollow.

[0009] The wire body consists of, from the inside out, a core, a protective layer, a shielding layer, and an outer sheath. The outer surface of the core is wrapped with a protective layer, the outer surface of the protective layer is wrapped with a shielding layer, and the outer surface of the shielding layer is wrapped with an outer sheath.

[0010] The outer surface of the head is provided with several elongated holes, which are filled with conductive inserts. The shielding layer inside the wire is partially peeled off and soldered onto the conductive inserts.

[0011] The end of the wire core is fixedly connected to a three-prong plug.

[0012] Preferably, in any of the above embodiments, the wire body is thermally connected to the end, and the end is thermally connected to or bonded to the seat.

[0013] The above technical solution involves adding a conductive shielding layer between the existing outer sheath and the wire core. This is crucial for EMI prevention.

[0014] Shielding material selection: Consider woven metal mesh (such as tin-plated copper wire braided mesh). It has good flexibility, is easy to process, and provides excellent shielding effect (high coverage). Shielding structure: The conductive shielding layer is tightly wrapped around the outside of the core and protective layer, and then covered with the existing outer sheath. Several elongated holes on the end surface are specially treated to make them conductive and reliably connected to the newly added internal shielding layer.

[0015] During the injection molding of the end cap, prefabricated conductive metal inserts (such as metal sheets or rings) are embedded in the elongated hole area, or conductive fillers (such as carbon fiber or metal powder) are mixed into the plastic raw material to create a localized conductive area in the elongated hole region. Shielding layer connection to the end cap: Inside the end cap (where the wire enters the end cap), the conductive shielding layer inside the wire body is carefully peeled off and securely welded, crimped, or clamped to the specially designed conductive area, i.e., the conductive insert, on the end cap. External interference electromagnetic field → absorbed / reflected by the conductive shielding layer in the wire body. Interference current absorbed by the shielding layer → conducted to the connection point inside the end cap. Interference current → passes through the metallized / conductive elongated hole area of ​​the end cap. Clever use of the elongated hole as a key grounding point: The elongated hole on the end cap, originally used only for heat dissipation, weight reduction, or positioning, is innovatively transformed into the lead-out end of the shielding layer and the starting point of the grounding path, giving it a new function. This is a clever structural reuse. A clear and continuous internal electromagnetic interference suppression path (shielding layer -> end cap connection -> elongated hole) is designed, ensuring the shielding effect.

[0016] Preferably, in any of the above embodiments, the end sleeve is hexagonal and is located on the outside of the three-pronged plug.

[0017] The above technical solution is adopted as follows: Main structure of the bus: Wire body: The main transmission part of the bus. Terminal: A connector plastic housing fixed to the end of the wire body, serving as a connection transition and protection. Socket: A second-level plastic housing fixed to the front of the terminal, providing auxiliary fixing and installation positioning features. End sleeve: A hexagonal (preferably) sleeve fixed to the front end of the socket, surrounding the three-prong plug, providing mechanical protection and anti-touch protection. Three-prong plug: A metal plug that connects to the end of the wire core (e.g., for mains power connection).

[0018] Preferably, in any of the above solutions, the core material is copper and the protective layer material is PVC.

[0019] Layered structure of the conductor (EMI-resistant core): Core: Located at the very center, this conductor carries the main current or signal. High-purity copper (such as oxygen-free copper) is preferred to ensure excellent conductivity.

[0020] Protective layer: Directly and tightly wrapped around the outer surface of a single core or a group of cores. The preferred material is polyvinyl chloride (PVC), providing basic insulation protection to prevent short circuits between cores and with the shielding layer.

[0021] Shielding Layer: The core improved layer of this invention, tightly wrapped around the outer surface of the protective layer. This layer preferably uses a tin-plated copper wire braided mesh structure. Its advantages are: High coverage: The braided structure allows it to tightly cover the underlying protective layer, achieving a coverage rate of over 95%, effectively blocking external electromagnetic field intrusion and internal signal radiation. Excellent flexibility: It easily bends with the wire without affecting the overall flexibility of the bus. Ease of processing: Facilitates subsequent stripping and connection operations at the ends.

[0022] Outer Sheath: Wrapped in the outermost layer, covering the entire shielding layer. The preferred material is rubber with good weather resistance and abrasion resistance (such as neoprene or thermoplastic elastomer TPE), providing physical protection (scratch resistance, impact resistance) and environmental protection (waterproof, oil-proof, flame retardant).

[0023] Preferably, in any of the above solutions, the shielding layer is a copper wire braided mesh, and the outer skin is made of rubber.

[0024] Preferably, the conductive insert is made of carbon fiber, as described in any of the above embodiments.

[0025] Compared with the prior art, the advantages and beneficial effects of this utility model are as follows:

[0026] The electromagnetic interference-resistant circuit connection bus has several elongated holes on its end surface that are specially treated to make them conductive and reliably connected to the newly added internal shielding layer.

[0027] During the injection molding of the end, prefabricated metal conductive inserts (such as metal sheets or rings) are embedded in the elongated hole area, or conductive fillers (such as carbon fiber or metal powder) are mixed into the plastic raw material to create a localized conductive area in the elongated hole area. Shielding layer and end connection: Inside the end (where the wire enters the end), the conductive shielding layer inside the wire body is carefully peeled off and firmly welded, crimped, or clamped to the specially designed conductive area, i.e., the conductive insert, on the end. External interference electromagnetic field → absorbed / reflected by the conductive shielding layer in the wire body. Interference current absorbed by the shielding layer → conducted to the connection point inside the end. Interference current → passes through the metallized / conductive elongated hole area of ​​the end. Clever use of the elongated hole as a key grounding point: The elongated hole on the end, originally used only for heat dissipation, weight reduction, or positioning, is innovatively transformed into the lead-out end of the shielding layer and the starting point of the grounding path, giving it a new function. This is a clever structural reuse. A clear and continuous internal electromagnetic interference suppression path is designed (shielding layer > end connection > elongated hole). This ensures effective shielding, and interference energy is effectively diverted.

[0028] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0029] The above and / or additional aspects and advantages of this utility model will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0030] Figure 1 This is a first-view structural schematic diagram of the present invention;

[0031] Figure 2This is a structural schematic diagram of the present invention from a second perspective;

[0032] Figure 3 This is a schematic diagram of the layer structure of the line body of this utility model;

[0033] Figure 4 This is a schematic diagram of the connection structure of the shielding layer of this utility model.

[0034] In the diagram: 1-Wire body, 2-End, 3-Socket, 4-End sleeve, 5-Wire core, 6-Protective layer, 7-Shielding layer, 8-Outer sheath, 9-Elongated hole, 10-Conductive insert, 11-Three-prong plug. Detailed Implementation

[0035] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0036] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0037] like Figure 1-4 As shown, the electromagnetic interference-resistant circuit connection bus includes a wire body 1, a terminal 2, a connector 3, and a sleeve 4. The terminal 2 is fixedly connected to the end of the wire body 1, the connector 3 is fixedly connected to the end of the terminal 2, and the sleeve 4 is fixedly connected to the end of the connector 3. The sleeve 4 is hollow.

[0038] The wire body 1 consists of wire core 5, protective layer 6, shielding layer 7, and outer sheath 8 from the inside out. The outer surface of wire core 5 is wrapped with a protective layer 6, the outer surface of protective layer 6 is wrapped with a shielding layer 7, and the outer surface of shielding layer 7 is wrapped with an outer sheath 8.

[0039] The outer surface of the head 3 is provided with several elongated holes 9, and the elongated holes 9 are filled with conductive inserts 10. The shielding layer 7 inside the wire 1 is partially peeled off and soldered onto the conductive inserts 10.

[0040] The end of the wire core 5 is fixedly connected to a three-prong plug 11.

[0041] Example 1: The wire body 1 is thermally connected to the end 2, and the end 2 is thermally connected to or bonded to the connector. The end sleeve 4 is hexagonal and located outside the three-prong plug 11. The wire core 5 is made of copper, and the protective layer 6 is made of PVC. The shielding layer 7 is specifically a copper wire braided mesh, and the outer sheath 8 is made of rubber. The conductive insert 10 is made of carbon fiber.

[0042] Example 2: Add a conductive shielding layer 7 between the existing outer sheath 8 and the wire core 5. This is crucial for EMI prevention.

[0043] Material selection for shielding layer 7: Consider woven metal mesh (such as tin-plated copper wire mesh). It has good flexibility, is easy to process, and has excellent shielding effect (high coverage). Structure of shielding layer 7: The conductive shielding layer 7 is tightly wrapped around the outside of the core 5 and the protective layer 6, and then the existing outer sheath 8 is wrapped around it.

[0044] The working principle of this utility model is as follows:

[0045] Bus manufacturing process: Wire preparation: manufacture four layers of wire body 1, then twist copper wire core 5, extrude and wrap PVC protective layer 6, braid tinned copper wire shielding layer 7, extrude and wrap rubber outer sheath 8.

[0046] Pre-installation of end assembly: Pre-positioning of conductive insert 10: Method A: Precisely position the metal conductive part at the corresponding position of the elongated hole 9 in the injection mold.

[0047] Injection molding: Injection mold end 2, seat 3 (including elongated hole 9 and conductive insert 10), and end sleeve 4 separately. During injection molding of seat 3, ensure that the conductivity of the area where the conductive insert 10 is embedded meets the standard. Assemble seat end: Fix seat 3 and end 2 together by hot melt or adhesive.

[0048] Wire end processing and connection: Cut the outer sheath 8 and shielding layer 7 at a predetermined position (near the connection point of end 2) and peel back an appropriate length. Carefully fold the exposed copper wire braided shielding layer 7 outward or leave a neat bundle structure. Solder or crimp the pins of the three-prong plug 11 to the processed end of the wire core 5. Pass the end of the wire 1 with the three-prong plug 11 through the end sleeve 4 and insert it into the connector 3 / end 2 assembly, so that the three-prong plug 11 protrudes from the hollow part of the end sleeve 4. Tightly wrap or lay the folded copper wire braided shielding layer 7 around or flatten it in the corresponding conductive insert 10 area inside the connector 3.

[0049] Soldering: Reliably solder the shielding layer 7 to the conductive insert 10 using solder or a spot welder (temperature approximately 380±20℃, time <3 seconds). Port potting and fixing: Potting epoxy resin or hot melt adhesive at the cable entry point of end 2 for stress relief and sealing. Finally fixing the end of wire body 1 to the end of end 2 by heat pressing or bonding.

[0050] Inspection: Test the bus continuity, insulation, and grounding continuity of the conductive area between shielding layer 7 and elongated hole 9 (resistance <10mΩ).

[0051] Electromagnetic Interference Suppression Mechanism: Electric / Magnetic Field Shielding: When an external electromagnetic field (electric field E or magnetic field H) reaches this bus: High-frequency electromagnetic waves induce eddy currents on the surface of the copper wire braided mesh of shielding layer 7. These eddy currents generate a reverse magnetic field (following Lenz's law), which cancels out part of the incident electromagnetic field. At the same time, the braided mesh forms a nearly continuous Faraday cage, with the internal conductor (core 5) in a low-impedance region with zero (or near-zero) potential, forcing most electric field lines to terminate at the surface of shielding layer 7 and be conducted away.

[0052] Interference current conduction: Interference currents absorbed by shielding layer 7 (originating from eddy currents and coupling) are efficiently conducted to the connector or device at the end of the bus via a carefully designed short path: shielding layer 7 stripped section -> solder joint -> conductive insert 10 -> conductive area of ​​elongated hole 9. When the bus is connected to mains power via three-pin connector 11 or the connected device has effective grounding, the interference current is ultimately discharged to ground or system ground through the device housing or dedicated grounding terminal contacted by the conductive area of ​​elongated hole 9, preventing it from inducing noise voltage on sensitive circuits.

[0053] Crosstalk suppression: Shielding layer 7 also isolates potential electromagnetic coupling (crosstalk) between internal conductors. Advantages of the functional grounding via the elongated hole 9: Low impedance: The short and direct solder connection path (shielding layer 7 -> conductive insert 10) significantly reduces the inductive reactance and resistance of the grounding loop. High reliability: Soldering provides a stronger, oxidation-resistant, and resistance-stable connection than crimping or spring contact; the conductive insert 10 is tightly bonded to the plastic body with no risk of loosening.

[0054] Reusability and compactness of structure: The existing heat dissipation / structural holes are cleverly used as high-performance grounding leads, avoiding the addition of extra components and maintaining the small size of the connector.

[0055] Compared with the prior art, the present invention has the following advantages:

[0056] The electromagnetic interference-resistant circuit connection bus has several elongated holes 9 on the surface of the end 2 that are specially treated to make them conductive and reliably connected to the newly added shielding layer 7 inside.

[0057] During the injection molding of end 2, a prefabricated metal conductive insert 10 (such as a metal sheet or metal ring) is embedded in the elongated hole 9 area, or conductive fillers (such as carbon fiber or metal powder) are mixed into the plastic raw material to form a local conductive area in the elongated hole area. The shielding layer 7 is connected to end 2: Inside end 2 (where the wire 1 enters end 2), the conductive shielding layer 7 inside the wire 1 is carefully peeled off and firmly welded, crimped, or clamped to the specially designed conductive area of ​​end 2, i.e., the conductive insert 10. External interference electromagnetic field → absorbed / reflected by the conductive shielding layer 7 in the wire 1. Interference current absorbed by shielding layer 7 → conducted to the connection point inside end 2. Interference current → passes through the metallized / conductive elongated hole 9 area of ​​end 2. Clever use of elongated hole 7 as a key grounding point: The elongated hole 7 of end 2, originally only used for heat dissipation, weight reduction, or positioning, is innovatively transformed into the lead-out end of shielding layer 7 and the starting point of the grounding path, giving it a new function. This is a clever structural reuse. A clear and continuous internal electromagnetic interference suppression path was designed (shielding layer 7 -> end 2 connection -> elongated hole 9). This ensures effective shielding and effectively diverts interference energy.

Claims

1. A circuit connection bus that is resistant to electromagnetic interference, characterized in that, It includes a wire body (1), an end (2), a base (3), and an end sleeve (4). The end of the wire body (1) is fixedly connected to the end (2), the end of the end (2) is fixedly connected to the base (3), and the end of the base (3) is fixedly connected to the end sleeve (4). The end sleeve (4) is hollow. The wire body (1) consists of a wire core (5), a protective layer (6), a shielding layer (7), and an outer sheath (8) from the inside out. The outer surface of the wire core (5) is wrapped with a protective layer (6), the outer surface of the protective layer (6) is wrapped with a shielding layer (7), and the outer surface of the shielding layer (7) is wrapped with an outer sheath (8). The outer surface of the head (3) is provided with several elongated holes (9), and the elongated holes (9) are filled with conductive inserts (10). The shielding layer (7) inside the wire (1) is partially peeled off and welded to the conductive inserts (10). The end of the wire core (5) is fixedly connected to a three-prong plug (11).

2. The electromagnetic interference-resistant circuit connection bus as described in claim 1, characterized in that: The line body (1) is thermally connected to the end (2), and the end (2) is thermally connected to or bonded to the seat.

3. The electromagnetic interference-resistant circuit connection bus as described in claim 2, characterized in that: The end sleeve (4) is hexagonal and is located on the outside of the three-prong plug (11).

4. The electromagnetic interference-resistant circuit connection bus as described in claim 3, characterized in that: The core (5) is made of copper, and the protective layer (6) is made of PVC.

5. The electromagnetic interference-resistant circuit connection bus as described in claim 4, characterized in that: The shielding layer (7) is specifically a copper wire mesh, and the outer skin (8) is made of rubber.

6. The electromagnetic interference-resistant circuit connection bus as described in claim 5, characterized in that: The conductive insert (10) is made of carbon fiber.

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