Flexible Magnetic Shielding Sheath for Vehicle Cable Routing
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Solution Overview
Problem
Existing magnetic shielding solutions for electric cables in vehicles are not suitable due to their bulkiness and the difficulty in molding materials with high relative permeability, such as mumetal or permalloy, within the confined space of a vehicle.
Innovation Solution
A flexible magnetic shielding sheath for electric cables composed of elongated elements made of electrically conductive materials and materials with sufficient magnetic properties, assembled in a crisscross manner or encircling configuration, and produced from an initially flat sheet that can be wound around the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If materials with very high relative permeability (such as mumetal or permalloy) are used for magnetic shielding, then the shielding effectiveness is improved, but the ease of manufacture deteriorates due to difficulty in molding and expensive treatment operations
Solution Approach 1:
The shielding sheath is constructed from discrete elongated elements (wires or strips) that are assembled together in a crisscross or encircling pattern, rather than using a monolithic high-permeability material. This segmentation allows the shielding function to be achieved through the collective effect of multiple simpler elements, avoiding the molding and treatment difficulties of traditional materials like mumetal while maintaining effective magnetic shielding.
Solution Approach 2:
The shielding sheath combines elongated elements of a first type made of electrically conductive material with elongated elements of a second type made of material having magnetic properties. This composite structure integrates both electrical conductivity (for return current path) and magnetic shielding capabilities, achieving dual functionality without requiring expensive specialized materials or complex manufacturing processes.
2Object-affected harmful factors
If rigid magnetic shielding structures are used, then the shielding effectiveness is improved, but the adaptability to spatial constraints deteriorates
Solution Approach 1:
The shielding sheath is designed as a flexible structure that can dynamically adapt to the cable's path and the available space in the vehicle. The elongated elements are arranged in a configuration that allows the sheath to bend and conform to spatial constraints while maintaining its shielding effectiveness, unlike rigid traditional shielding structures.
Solution Approach 2:
The shielding sheath is constructed as a flexible tubular casing from assembled elongated elements, enabling it to wrap around cables and adapt to the confined and irregular spaces within a vehicle. This flexible structure maintains magnetic shielding effectiveness while providing the necessary adaptability to fit various installation geometries.
3Device complexity
If a return path through the chassis is used, then the electrical connection is simplified, but the magnetic field attenuation deteriorates due to high impedance from heterogeneous structure
Solution Approach 1:
The shielding sheath performs multiple functions simultaneously: it provides magnetic shielding, establishes a low-impedance return current path, and offers mechanical protection for the cable. By integrating the return conductor function into the shielding structure itself, the system eliminates the need to rely on the chassis for current return, thereby reducing magnetic field intensity while maintaining electrical connection simplicity.
Solution Approach 2:
The shielding sheath acts as an intermediary return conductor between the cable and the generator, providing a dedicated low-impedance path for return current. This intermediary structure bypasses the heterogeneous chassis path, effectively reducing the magnetic field generated by return current while maintaining electrical connectivity.
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 the magnetic component of the electromagnetic field emitted by the cable, reduces the intensity of the magnetic field, and is adaptable to the spatial constraints of a vehicle, providing a cost-effective and modular solution.
Implementation Method 1
the current in the shielding sheath creates a magnetic field opposite to the disturbing magnetic field created by the current flowing in the cable
Implementation Method 2
the elongated elements made of a material having magnetic properties make it possible to provide the shielding against the resulting magnetic field
Data Source
AI summary
The sheath forms, in the mounted state, a flexible tubular casing configured to receive the cable.The sheath includes elongated elements such as wires or strips, which include elongated elements of a first type, made of at least one electrically conductive material; and elongated elements of a second type, different from the first type, made of at least one material having sufficient magnetic properties to produce the shielding effect. The elongated elements are assembled in a crisscross manner and/or forming an encircling, and the sheath is produced in the form of an initially substantially flat sheet, suitable for being wound around the cable.