Deep-Drawn Shielding Shell for High-Voltage Connector Uniformity
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Solution Overview
Problem
The existing high-voltage connector shielding shells require multiple layers of sheet metal, leading to thicker structures, increased material and manufacturing costs, and non-uniform thickness.
Innovation Solution
An integrated barrel-shaped electromagnetic shielding shell with a uniform thickness, formed by a deep drawing process, eliminating structural slits and overlapping materials, featuring through holes, protection rings, and clamping holes for terminal passage and secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers of sheet metal are overlapped after bending, then the shielding shell can be formed, but the partial structure becomes thicker and material cost increases
Solution Approach 1:
The patent merges multiple sheet metal layers into a single integrated shell structure. The shell is formed as one continuous piece with through holes for terminals, eliminating the need to overlap multiple bent sheet metal layers. This integration maintains electromagnetic shielding effectiveness while reducing material quantity and eliminating local thickening.
Solution Approach 2:
The patent changes the structural parameter from multi-layer overlapped configuration to single-layer integrated configuration. The shell maintains adequate thickness for shielding performance but distributes it uniformly throughout the structure rather than creating localized thick sections through layer overlap.
2Reliability
If multiple layers of sheet metal are overlapped after bending, then the shielding shell can be formed, but the structure thickness becomes non-uniform
Solution Approach 1:
The patent combines multiple manufacturing operations into a single forming process that produces an integrated shell. The shell is formed with consistent wall thickness throughout, avoiding the thickness variations that occur when multiple sheet metal layers are overlapped and bonded together.
3Ease of manufacture
If sheet metal bending process is used, then the shielding shell can be formed, but the bending structure becomes complicated with structural slits
Solution Approach 1:
The patent combines the shell structure with terminal passage features into a single integrated component. The through holes for terminals are formed directly in the shell during the same manufacturing process, eliminating the need for separate bending operations and structural slits that would be required in traditional multi-layer constructions.
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
Improves current passing capacity and electromagnetic shielding performance, reduces material usage and costs, and ensures uniform thickness, minimizing space occupation while maintaining effective shielding.
Implementation Method 1
The integrated barrel-shaped structure is a structure formed by a deep drawing process
Data Source
AI summary
The present application provides a high-voltage connector and an electromagnetic shielding shell for the high-voltage connector, the electromagnetic shielding shell has an integrated barrel-shaped structure formed by a deep drawing process, and integrated barrel-shaped structure includes a barrel wall and a barrel bottom that are connected to each other. By providing an integrated barrel-shaped structure formed by the deep drawing process, the entire electromagnetic shielding shell does not have structural slits, thereby improving the current passing capacity and electromagnetic shielding performance, and there is no overlap of multiple sheet metal materials in the structure of the electromagnetic shielding shell, and can increase the thickness of the electromagnetic shielding shell under the same conditions, and it can also make the structure thickness of the electromagnetic shielding shell have better uniformity, avoid the situation of thick local structure, and the space occupied by the electromagnetic shielding shell in the high-voltage connector is reduced and materials are saved, which can reduce the material cost and manufacturing cost of the product.