High-Voltage Connector Shielding Shell for EMI-Safe EV Connections
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Solution Overview
Problem
The existing high-voltage connecting mechanisms for electric vehicles have complex structures, high costs, and are prone to electromagnetic interference due to the use of copper wires and metal shielding covers, which are difficult to process and assemble, leading to safety issues and increased costs.
Innovation Solution
A high-voltage connecting mechanism with integrally injection-molded male-end and female-end shielding shells that provide effective electromagnetic shielding through plugging cooperation with the cable's shielding layer, reducing the need for complex assembly and metal shielding covers, and incorporating a temperature measuring structure for safety monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If metal shielding covers are used to shield electromagnetic interference, then electromagnetic shielding effect is improved, but processing difficulty and assembly complexity increase
Solution Approach 1:
The patent combines the shielding function with the connector housing itself. The housing is made of conductive material and integrates the shielding function directly into the structural component, eliminating the need for separate metal shielding covers. This merging of functions reduces the number of parts and simplifies assembly while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The connector housing serves multiple functions: it provides structural support, enables electrical connection, and simultaneously acts as an electromagnetic shield. By making the housing conductive and designing it to enclose the internal components, it performs both mechanical and electromagnetic shielding functions, reducing overall device complexity.
2Object-affected harmful factors
If metal shielding covers are used to shield electromagnetic interference, then electromagnetic shielding effect is improved, but processing difficulty increases
Solution Approach 1:
The shielding function is merged into the housing manufacturing process itself. The housing is molded or formed as a single conductive piece that inherently provides shielding, eliminating the need for separate metal cover processing and assembly operations.
Solution Approach 2:
The patent employs conductive materials for the housing that provide both structural integrity and electromagnetic shielding properties. This use of functionally graded or composite conductive materials allows the housing to serve dual purposes without requiring additional metal shielding components.
3Reliability
If traditional assembled connectors with copper wires are used, then electrical conduction is achieved, but structure complexity and cost increase
Solution Approach 1:
The patent integrates the cable, terminal, and connector housing into a single molded structure. The housing is formed integrally with the cable and terminal components, eliminating the need for separate assembly of copper wires and metal connectors. This integration maintains electrical conduction while dramatically simplifying the overall structure.
Solution Approach 2:
The connector is designed as a modular integrated unit that can be separately manufactured and then connected to other systems. This segmentation allows for simplified manufacturing of the connector assembly itself, while the integrated design reduces internal complexity.
Data Source
AI summary
The present disclosure provides a high-voltage connecting mechanism, an electrical energy transmission apparatus and a motor vehicle. The high-voltage connecting mechanism includes: a male-end connecting mechanism and a female-end connecting mechanism, in which the male-end connecting mechanism comprises a first cable, a plug-in terminal, a male-end housing integrally formed with the first cable and the plug-in terminal, and a male-end shielding shell disposed outside the male-end housing; the female-end connecting mechanism includes a mating terminal, a second cable, a mating terminal, a female-end housing integrally formed with the second cable and the mating terminal. By means of plugging cooperation of the male-end shielding shell and the female-end shielding shell, and an electrical connection with a cable shielding layer, an electromagnetic interference in the high-voltage connecting mechanism can be effectively shielded, and an electromagnetic interference with other devices can be reduced.