Cable Shielding Connection Assembly for Stable EMI Continuity
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Solution Overview
Problem
Current cable assemblies fail to form a stable and effective connection between shielding nets, leading to inadequate electromagnetic shielding between cable cores, which affects the electromagnetic interference protection in vehicles equipped with batteries.
Innovation Solution
A cable assembly with a shielding connection assembly that includes conductive devices and shielding internal and middle devices, which connect the shielding layers of two cables through everted portions and crimping or welding, ensuring continuity and stability of the shielding structure, thereby improving the electromagnetic shielding effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional shielding connection structures are used to butt two cables, then the cable assembly can be manufactured with simple structure, but the shielding nets cannot form a stable and effective connection, resulting in poor electromagnetic shielding effect
Solution Approach 1:
The shielding connection assembly is divided into multiple functional components: conductive devices for electrical connection, shielding internal devices for structural support, shielding middle devices for connection, and shielding external devices for protection. This segmentation allows each component to perform its specific function optimally while maintaining overall stability and effectiveness of the shielding connection.
Solution Approach 2:
The shielding connection assembly adopts a nested structure where shielding internal devices are placed inside shielding middle devices, which are in turn placed inside shielding external devices. This nested arrangement maximizes space utilization, provides multiple levels of protection, and ensures stable connection while managing the complexity through organized hierarchical structure.
2Object-affected harmful factors
If shielding layers are connected without proper connection structures, then the manufacturing process is simple, but the electromagnetic shielding effect between cable cores is insufficient
Solution Approach 1:
The shielding layers are pre-prepared with specific structures and properties before connection. The conductive devices are pre-formed with appropriate geometries, and the shielding internal and middle devices are pre-assembled. This preliminary preparation ensures that when the cables are connected, the electromagnetic shielding effect is immediately effective without requiring complex post-connection adjustments.
Solution Approach 2:
Conductive devices serve as intermediaries between the shielding layers of the two cables, providing a reliable electrical connection path. The shielding middle devices act as intermediaries to join the conductive devices to the shielding layers. These intermediary components bridge the gap between the shielding layers, ensuring effective electromagnetic shielding while simplifying the manufacturing process through standardized connection interfaces.
3Reliability
If multiple shielding devices are used to connect shielding layers, then the electromagnetic shielding performance is improved, but the structural complexity and assembly difficulty increase
Solution Approach 1:
Multiple shielding devices are merged into an integrated shielding connection assembly where the conductive devices, shielding internal devices, shielding middle devices, and shielding external devices work together as a unified system. This merging maintains the electromagnetic shielding performance benefits of multiple components while reducing assembly difficulty through pre-assembly and standardized interfaces.
Solution Approach 2:
The shielding connection assembly is designed to be self-aligning and self-securing. The nested structure of shielding internal, middle, and external devices provides automatic positioning and secure fixation during assembly. The conductive devices are configured to automatically connect to the shielding layers when the assembly is performed, reducing the need for complex alignment procedures and manual adjustments.
Data Source
AI summary
The present disclosure provides a cable assembly and a manufacturing method therefore. The cable assembly provided by the present disclosure includes a first cable, a second cable and a shielding connection assembly. The first cable includes a first cable core and a first shielding layer. A first protective layer is wrapped around an outer side of the first cable core, and the first shielding layer is disposed on an outer side of the first protective layer. The second cable includes a second cable core and a second shielding layer. A second protective layer is wrapped around an outer side of the second cable core, and the second shielding layer is disposed on an outer side of the second protective layer. The shielding connection assembly includes at least one shielding device, and at least one shielding device is connected to the first shielding layer and the second shielding layer.