High-Voltage Cable Distributor With Continuous Shielded Connections
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Solution Overview
Problem
High-voltage electrical systems in vehicles require effective shielding of individual cables to prevent electrical field interference, while existing solutions often complicate assembly and may lead to short-circuits due to high operating voltages.
Innovation Solution
A cable distributor with an electrically conductive shield housing and conical support sleeves for easy shield contact, combined with insulating inserts to prevent short-circuits and resilient tabs for strain relief, allowing for reliable and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If individual shielded cables are used for high-voltage connections, then shielding effectiveness against electrical fields is improved, but assembly complexity increases due to the need to contact and connect multiple shields
Solution Approach 1:
Multiple individual cable shields are merged into a single common shield structure within the cable distributor housing. This allows all shields to be connected together through a unified path rather than requiring separate connections for each cable, thereby maintaining shielding effectiveness while significantly simplifying the assembly process.
Solution Approach 2:
A conductive connection element is introduced as an intermediary component to facilitate the connection between individual cable shields and the common shield. This mediator element simplifies the contacting process by providing a standardized interface that automatically establishes electrical connection when cables are inserted into the distributor.
2Loss of substance
If higher operating voltages are used, then material and weight savings are achieved through smaller cable cross-sections, but the risk of short-circuits increases
Solution Approach 1:
The cable distributor internally segments different electrical circuits through insulating partitions and structured arrangement of connection elements. This segmentation prevents unintended electrical contact between high-voltage lines, thereby reducing short-circuit risk while allowing the use of smaller, lighter cables for high-voltage applications.
Solution Approach 2:
The cable distributor design incorporates preliminary protective measures through its structured housing and insulating elements that prevent short-circuits before they can occur. The pre-configured isolation barriers and controlled contact paths actively counteract the increased short-circuit risk associated with high-voltage operation.
3Object-affected harmful factors
If continuous shielding is implemented for high-voltage cables, then electrical field interference is reduced, but the complexity of connecting shields at the distributor increases
Solution Approach 1:
The patent merges multiple individual cable shields into a single common shield structure within the cable distributor housing. This allows all shields to be connected together through a unified path rather than requiring separate connections for each cable, thereby maintaining shielding effectiveness while significantly simplifying the assembly process.
4Ease of manufacture
If a simple cable distributor design is used, then manufacturing and assembly are simplified, but adequate shielding and insulation for high-voltage applications may not be achieved
Solution Approach 1:
The cable distributor housing serves multiple functions simultaneously: it provides the structural enclosure, acts as the common shield connection path, incorporates insulating partitions for circuit separation, and includes features for cable fixation and strain relief. This multi-functionality achieves adequate shielding and insulation without requiring additional separate components, thereby maintaining manufacturing simplicity.
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 provides continuous shielding against high electrical fields, simplifies assembly, and prevents short-circuits, making it suitable for high-voltage applications in electric vehicles.
Implementation Method 1
The shields of the connected individual cables are connected to each other by means of an electrically conductive shield housing. The shield housing encloses the entire area where the individual cables are connected to each other and in this way provides effective shielding from electrical fields
Implementation Method 2
there are conical support sleeves arranged under the shields of the individual cables. The conical support sleeves raise the shields of the individual cables and thereby simplify the electrical contacting of the shields
Implementation Method 3
the cable distributor has electrically conductive connection components that are provided with receivers, the surfaces of which are realized so as to be complementary to the shape of the conical support sleeves. The connection components are arranged between the individual cables to be electrically connected, and effect an electrical contact to the shields of the individual cables
Implementation Method 4
The insulating insert ensures that no short-circuit occurs inside the cable distributor as a result of touching of contact points or conductors that are at a different electrical potential
Implementation Method 5
the outer housing has resilient tabs that clamp an insulation of an individual cable. This design allows the outer housing to provide strain relief for the individual cables
Data Source
AI summary
A cable distributor for individual cables that are shielded by an electrically conductive shield. The cable distributor has an electrically insulating outer housing, which receives a connection piece at which at least two individual cables are connected to each another. The shields of the connected individual cables are connected to each other by means of an electrically conductive shield housing, as a result of which a continuous shielding of the current-carrying parts of the cable distributor is achieved. A method for producing such a cable distributor is also proposed.