High-Voltage Cable Joint Structure for EV Safety
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Solution Overview
Problem
The connection between high-voltage cables and cable connectors in new-energy vehicles often results in insufficient safe distance between the annular terminal and shielding layer, leading to electric leakage, and the shielding layer is prone to damage due to a large cable diameter and improper insertion.
Innovation Solution
A joint structure for high-voltage cables featuring a cable core wrapped with inner and outer insulating layers, where a section of these layers is stripped and wrapped with a heat-shrinkable tube and copper foil, ensuring safe isolation and preventing damage by maintaining a safe distance and reinforcing the shielding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shielding layer is exposed to exterior at a certain size to contact the cable connector, then the shielding function is realized, but the safe distance between the annular terminal and the shielding layer becomes insufficient causing electric leakage
Solution Approach 1:
The patent introduces an intermediary insulating structure (including the insulating layer and heat-shrinkable tube) between the annular terminal and the shielding layer. This intermediary structure maintains the necessary electrical isolation while allowing the shielding layer to be exposed for connector contact, thus preventing electric leakage while preserving the shielding function.
Solution Approach 2:
The patent extends the insulating structure in the axial dimension (along the cable length) by using a heat-shrinkable tube that covers a significant portion of the cable length. This dimensional extension ensures adequate safe distance between the high-voltage terminal and the shielding layer without compromising the shielding layer's exposure for electrical connection.
2Strength
If the cable diameter at the tail of the annular terminal is increased, then the structural strength is improved, but the tail cannot be inserted into the cable connector
Solution Approach 1:
The patent segments the cable structure into different functional zones: a reinforced section with the annular terminal for strength, and a tapered transition section at the tail that reduces the diameter. This segmentation allows the cable to have both high structural strength where needed and reduced diameter for connector insertion where required.
Solution Approach 2:
The patent applies different structural qualities to different parts of the cable. The annular terminal region has increased diameter and reinforcement for strength, while the tail end has a reduced diameter through tapered design. This local differentiation of structural properties resolves the contradiction between needing strength and needing small insertion diameter.
3Reliability
If the shielding layer is exposed for connector contact, then the shielding function is achieved, but the shielding layer is easily scraped by the cable connector to be damaged
Solution Approach 1:
The patent provides beforehand protection to the shielding layer by covering the exposed portion with a heat-shrinkable tube after connector assembly. This pre-applied protective layer prevents the shielding layer from being scraped or damaged during installation and use, while not interfering with the electrical contact function.
Solution Approach 2:
The patent uses a thin-film heat-shrinkable tube as a flexible protective shell over the shielding layer. This thin film provides mechanical protection against scraping and damage while remaining flexible enough to conform to the cable structure and not interfere with the shielding layer's electrical contact with the connector.
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 isolates high voltage from low voltage, prevents electric leakage, and strengthens the shielding layer to avoid damage during installation, ensuring reliable and safe connections.
Implementation Method 1
a section of the inner insulating layer and of the outer insulating layer being stripped at an end of the cable core... an axial spacing is provided between an end of the heat-shrinkable tube and the outer insulating layer
Implementation Method 2
the shielding layer within the spacing is wrapped by a copper foil... the shielding layer is connected externally to a cable connector via the copper foil
Implementation Method 3
the shielding layer is folded within the spacing, and the folded section is located between the inner-layer copper foil and the outer-layer copper foil
Data Source
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AI summary
The present disclosure discloses a joint structure of a high-voltage cable, including a cable core (7), the cable core (7) being wrapped from interior to exterior sequentially by an inner insulating layer (6), a shielding layer (8) and an outer insulating layer (5), a section of the inner insulating layer (6) and of the outer insulating layer (5) being stripped at an end of the cable core (7), and a length of the stripped section of the outer insulating layer (5) being greater than a length of the stripped section of the inner insulating layer (6), wherein the end of the cable core (7) is connected to an external terminal (9), a connection between the end of the cable core (7) and the external terminal (9) and an adjacent section of the inner insulating layer (6) are wrapped by a heat-shrinkable tube, a spacing is provided between an end of the heat-shrinkable tube and the outer insulating layer (5), the shielding layer (8) within the spacing is wrapped by a copper foil, and the shielding layer (8) is connected externally to a cable connector via the copper foil. The present disclosure improves the safety during connecting the cable connector to the high-voltage cable, can avoid a too large diameter at the tail end of the high-voltage cable, and can prevent the shielding layer (8) from being scraped by the cable connector to be damaged.