EV Charging Socket Shielding via Nested Braided Layers
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Solution Overview
Problem
Charging sockets for electric vehicles face disruptions due to electromagnetic interference affecting control signals during the charging process, which can impact the reliability of the charging process.
Innovation Solution
The charging socket incorporates a metallic braided shield for electromagnetic shielding, a crimped metallic sleeve with an annular spring for reliable electrical connection, and a screw dome with a ring cable lug for secure grounding, along with a protective plastic housing to mitigate interference and ensure reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metallic braided shield is added to shield against electromagnetic interference, then electromagnetic shielding capability is improved, but device complexity increases
Solution Approach 1:
The patent implements nested shielding structures where an inner braided shield and an outer shield are arranged concentrically around the power lines. The inner shield is positioned between the power lines and the outer shield, creating multiple layers of electromagnetic protection. This nested configuration maximizes shielding effectiveness while maintaining a compact structure that integrates seamlessly into the charging socket assembly.
Solution Approach 2:
The patent employs composite shielding structures combining different metallic materials with distinct properties. The inner shield uses a first metallic material optimized for high-frequency interference, while the outer shield uses a second metallic material with complementary characteristics. This composite approach provides broad-spectrum electromagnetic shielding across different frequency ranges, addressing various sources of interference simultaneously.
2Object-affected harmful factors
If multiple shielding layers are implemented, then electromagnetic shielding effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the shielding system into discrete, modular segments - separate inner and outer shields that can be manufactured independently using standard industrial processes. Each shield is supplied as a pre-formed component, allowing for specialized manufacturing optimization. The segmented design enables independent quality control and testing of each shielding layer before final assembly, simplifying the overall manufacturing workflow despite the multi-layer configuration.
Solution Approach 2:
The patent ensures that both the inner and outer shields are electrically connected to a common ground potential through dedicated grounding conductors. This equipotential configuration eliminates potential differences between shielding layers that could cause circulating currents or interference. By establishing a unified reference potential, the design simplifies the electrical connections required for multi-layer shielding and ensures predictable electromagnetic performance.
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 shields against electromagnetic interference, ensures reliable electrical connections, and protects the charging socket from mechanical damage and environmental ingress, enhancing the overall reliability and efficiency of the charging process.
Implementation Method 1
A metallic braided shield is arranged on top of this primary insulation layer. This braided shield provides electromagnetic shielding for the power conductor.
Implementation Method 2
The electrical connection between the contact lens and the respective shielding braid of the electrical power cables is established via the metallic sleeve and the ring spring arranged therein. This electrical contact has proven to be particularly reliable because it compensates for tolerances and mechanical movements of the contact elements during the insertion process.
Data Source
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AI summary
The invention relates to a charging socket (1) for an electric vehicle, wherein the charging socket (1) has at least two electrical power lines (2), wherein the power lines (2) each consist of a central metallic conductor (3), a first insulation (5) surrounding it, a metallic braided shield (4) arranged thereon and a second insulation (6) surrounding it, wherein the charging socket (1) has a metallic contact lens (7) which is electrically connected to the braided shields (4) of the at least two power lines (2), wherein the charging socket (1) has a screw-on dome (11) which is electrically connected to the contact lens (7) and to which an electrical shield conductor can be connected, which can be electrically connected to the charging socket (1) and/or the body of the electric vehicle.