Continuous EMI Shield for HV Connectors
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Solution Overview
Problem
High voltage electrical connectors often fail to adequately shield low voltage signals from interference, particularly in applications where power and signal pathways are in close proximity, such as in electric and hybrid electric vehicles, leading to significant concerns about electromagnetic interference (EMI).
Innovation Solution
A high voltage shielded electrical connector assembly is designed with a continuous EMI shield formed by the high voltage cap and plug shields, which secure within their respective housings, ensuring that both high voltage and low voltage pathways are protected from interference by forming a continuous EMI shield when mated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage pathways and connectors are placed in close proximity to low voltage pathways and connectors, then power transfer efficiency is improved, but electromagnetic interference between power and signal pathways increases
Solution Approach 1:
The connector is divided into separate high voltage and low voltage portions with distinct shielding. The high voltage shield and low voltage shield are segmented into separate components that can be independently configured and assembled, allowing each to provide optimized protection for its respective pathways while maintaining close proximity for efficient power transfer.
Solution Approach 2:
A continuous EMI shield acts as an intermediary barrier between the high voltage and low voltage pathways. This shield, formed by the combination of high voltage shield and low voltage shield, mediates the electromagnetic field interactions and prevents interference while allowing the pathways to remain in close proximity.
2Object-affected harmful factors
If shielding is added to protect low voltage signals from high voltage interference, then electromagnetic interference is reduced, but device complexity increases
Solution Approach 1:
The high voltage shield and low voltage shield are merged to form a continuous EMI shield when the connector portions are mated. This integration creates comprehensive protection without requiring separate complex shielding systems for each pathway, as the combined structure provides unified EMI protection.
Solution Approach 2:
The shields are nested within the respective connector housings, with the high voltage shield contained within the high voltage portion and the low voltage shield within the low voltage portion. This nested arrangement provides efficient space utilization and protects the pathways while maintaining a compact connector structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents interference between high voltage and low voltage pathways, ensuring reliable operation in applications where both types of signals coexist, such as in electric and hybrid electric vehicles, by creating a continuous EMI shield that secures the high voltage cap and plug shields within their housings.
Implementation Method 1
The high voltage cap shield and high voltage plug shield form a continuous EMI shield when the high voltage cap connector and the high voltage plug connector are mated
Data Source
AI summary
A high voltage (HV) shielded electrical connector assembly is disclosed. The HV connector assembly includes a HV connector sub-assembly including a HV cap connector and a HV plug connector, a HV interlock (HVIL), and a low voltage (LV) connector sub-assembly. The HV cap connector includes an HV cap outer housing, and HV cap inner housing, and a HV cap shield disposed therebetween, the HV cap shield secured within the HV cap outer housing, and the HV cap inner housing secured within the HV cap shield. The HV plug connector includes an HV plug outer housing, and HV plug inner housing, and a HV plug shield disposed therebetween, the HV plug shield secured within the HV plug outer housing and the HV plug inner housing secured within the HV plug shield. The HV cap shield and the HV plug shield form a continuous EMI shield when the HV plug connector and the HV cap connector are mated.