Housing with Integrated Conductive Layer for Shielded Power Cables
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Solution Overview
Problem
The existing systems for connecting motor vehicle power lines struggle to maintain sufficient shielding and electromagnetic compatibility, especially when high voltages and currents are involved, leading to laborious manual work and reduced efficiency in assembly.
Innovation Solution
A housing with an integrated electrically conductive layer overmoulded on both sides with plastic, which continues the shielding of the motor vehicle power line, allowing for efficient assembly and improved electromagnetic compatibility by balancing potentials and reducing electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a housing is used to connect conductors of motor vehicle power lines, then the connection function is achieved, but the shielding is interrupted and electromagnetic compatibility is reduced
Solution Approach 1:
The patent merges the housing structure with an integrated electrically conductive layer to continue the shielding function. The conductive layer is embedded within the housing body, combining the mechanical support function of the housing with the electromagnetic shielding function in a single integrated component, thereby maintaining shielding continuity without requiring separate manual shielding processing steps.
Solution Approach 2:
The housing is constructed as a composite structure with an electrically conductive layer integrated within an insulating housing material. This composite design allows the housing to simultaneously provide mechanical support, electrical insulation where needed, and continuous electromagnetic shielding through the conductive layer, resolving the contradiction between ease of manufacture and electromagnetic compatibility.
2Reliability
If manual work is used to continue the shielding of the power line, then the shielding continuity is maintained, but the assembly process becomes laborious and inefficient
Solution Approach 1:
The shielding function is merged into the housing structure itself through the integrated conductive layer. This eliminates the need for separate manual shielding continuation steps, as the housing automatically provides continuous shielding when assembled, thereby maintaining shielding reliability while dramatically improving assembly efficiency.
Solution Approach 2:
The housing with integrated conductive layer performs the shielding function automatically through its own structure. The conductive layer is pre-integrated into the housing, allowing the housing to self-provide shielding continuity without requiring external manual intervention or additional separate shielding components to be manually installed.
3Object-affected harmful factors
If the shielding is continued manually in the housing area, then the electromagnetic compatibility is maintained, but the number of work steps increases
Solution Approach 1:
The housing and shielding layer are merged into a single integrated component. The conductive layer is embedded within the housing structure during manufacturing, so that when the housing is assembled, the shielding is automatically continued without requiring separate manual work steps. This reduces device complexity by eliminating multiple independent components and assembly steps.
4Productivity
If an electrically conductive layer is integrated into the housing, then the shielding is continued efficiently, but the housing structure becomes more complex
Solution Approach 1:
The conductive layer is merged with the housing structure during manufacturing, creating an integrated component. While this adds complexity to the housing structure itself, it eliminates the need for separate shielding components and manual assembly steps, resulting in net simplification of the overall system and improved assembly efficiency.
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 enhances electromagnetic compatibility and simplifies the assembly process by maintaining shielding through the electrically conductive layer, reducing manual labor and ensuring effective protection against electromagnetic influences.
Implementation Method 1
the housing is made of plastic and has an electrically conductive layer integrated into the housing, with the electrically conductive layer being overmoulded with plastic on both sides for continuing the shielding of the motor vehicle power line
Data Source
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AI summary
The invention relates, among other things, to a housing for a motor vehicle power cable (1a) comprising a conductor (8a) and a shield (4a), the housing having a first connection area (22a, 22a') for the motor vehicle power cable (1a) and at least one further connection area (22b, 22b') for a further conductor (8b, 30'), wherein the housing allows an electrically conductive connection between the conductor (8a) of the motor vehicle power cable (1a) and the further conductor (8b, 30') within the housing (20, 20'). The objective of mounting shielded motor vehicle power cables as efficiently as possible while simultaneously achieving high electromagnetic compatibility is achieved by the housing (20, 20') having an electrically conductive layer (26, 26') integrated into the housing (20, 20') for extending the shield (4a) of the motor vehicle power cable (1a).