Cable Bushing With Integrated Contact Elements for Direct PCB Connection
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Solution Overview
Problem
Existing cable bushings in electric vehicles fail to provide adequate EMC protection and efficient assembly due to the need for cable stripping, crimping, and potential cable breaks during assembly, as well as insufficient consideration for high-voltage applications and leakage current prevention.
Innovation Solution
A cable bushing with contact elements protruding from the bushing housing for direct plug connection to the printed circuit board, featuring a shielding plate with crimp webs and lugs for secure cable connection, and a sealing mechanism to prevent leakage currents, facilitating assembly and enhancing EMC protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are stripped and crimped inside the control housing, then electrical connection to the printed circuit board is achieved, but assembly effort increases and cable breaks may occur
Solution Approach 1:
The contact elements are pre-assembled on the printed circuit board before the control housing is assembled. This preliminary action eliminates the need for cable stripping and crimping inside the control housing, reducing assembly effort while maintaining reliable electrical connections.
Solution Approach 2:
The cable bushing serves as an intermediary component that facilitates the connection between cables and the printed circuit board. It provides a structured interface with guide elements that align cables with contact elements, enabling reliable connections without direct manual crimping inside the control housing.
2Ease of operation
If cables are laid within the control housing, then electrical connections are established, but cables may be squeezed during subsequent assembly operations leading to cable breaks
Solution Approach 1:
Cables are routed through the cable bushing and connected to contact elements before the control housing is fully assembled. This preliminary routing protects cables from being squeezed during subsequent assembly operations, maintaining cable integrity while establishing electrical connections.
Solution Approach 2:
The cable bushing segments the cable routing path from the main control housing assembly process. By providing a dedicated entry point and guide elements, it isolates cables from compression forces generated during control housing assembly, preventing cable breaks.
3Object-affected harmful factors
If shielding is applied to cables in the region of the bushing housing, then EMC protection is improved, but assembly complexity increases
Solution Approach 1:
The shielding function is merged with the cable bushing structure itself. The bushing housing provides a shielded environment for cable connections, eliminating the need for separate shielding components and reducing assembly complexity while maintaining EMC protection.
Solution Approach 2:
The cable bushing serves multiple functions simultaneously: it provides mechanical guidance for cables, enables electrical connections through contact elements, and offers EMC protection through its shielded structure. This multi-functionality reduces overall assembly complexity while maintaining comprehensive protection.
4Reliability
If air gaps and leakage paths are prevented in high-voltage applications, then leakage current prevention is improved, but sealing complexity increases
Solution Approach 1:
The sealing function is merged with the cable bushing structure. The bushing housing provides integrated sealing that prevents air gaps and leakage paths between different polarities in high-voltage applications, eliminating the need for separate sealing components and reducing complexity.
Solution Approach 2:
The cable bushing utilizes composite material construction that combines insulating and sealing properties in a single structure. This composite design provides both electrical isolation and leak prevention without requiring multiple separate sealing elements, reducing overall complexity while maintaining reliability.
Data Source
AI summary
A cable bushing is disclosed for placement into a control housing surrounding a printed circuit board. The cable bushing includes a bushing housing comprising a locating surface, fastening means for fastening the bushing housing to the control housing, and retainers for at least two cables which are to be electrically connected to the printed circuit board. To facilitate the assembly of the cable bushing, the cable bushing housing is provided with contact elements that protrude from its front face, that are embodied to be adapted for plug contacting the printed circuit board, and that are electrically connected to the associated cables within the bushing housing. Also disclosed is the combination of a control housing and cable bushing and a printed circuit board housed in the control housing.