Multi-Core Connector Assembly With Insulated Skeletons for EV Cable Wear
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Solution Overview
Problem
Current multi-core copper cables used in new energy automotive connectors are heavy, expensive, and prone to damage from friction with the vehicle shell, leading to high-voltage discharges and potential traffic accidents.
Innovation Solution
A multi-core electric connector assembly featuring at least two electric connection skeletons with connectors at both ends, where the connection terminal is fixed to the connector, and insulating protective layers are used between and around the skeletons to reduce friction and prevent high-voltage discharges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-core copper cable is used in connector assembly, then electric conductivity is improved, but weight increases and cost increases
Solution Approach 1:
The patent changes the material parameter from traditional copper to aluminum alloy, achieving a balance between electrical conductivity and weight reduction. The aluminum alloy skeleton maintains sufficient conductivity while significantly reducing cable weight compared to multi-core copper cable.
Solution Approach 2:
The patent employs composite material structure by combining aluminum alloy skeleton with insulating protective layers and connectors. This composite approach allows optimization of each component's properties, achieving both light weight and reliable electrical connection.
2Reliability
If multi-core copper cable is used in connector assembly, then electric conductivity is improved, but cost increases
Solution Approach 1:
The patent changes the material parameter from expensive copper to more cost-effective aluminum alloy, significantly reducing material cost while maintaining acceptable electrical conductivity for automotive applications.
Solution Approach 2:
The patent uses homogeneous aluminum alloy material throughout the skeleton structure, simplifying manufacturing processes and reducing costs compared to multi-core copper cable assembly which requires complex twisting and joining of multiple copper strands.
3Reliability
If multi-core cable with large diameter is used, then electric conductivity is improved, but weight increases and friction with vehicle shell increases
Solution Approach 1:
The patent changes the structural parameter from large-diameter multi-core cable to compact single-skeleton design, reducing the outer diameter and thus minimizing friction contact with the vehicle shell during vehicle operation.
Solution Approach 2:
The patent applies a protective insulating layer that can be replaced if damaged, protecting the critical aluminum alloy skeleton from friction damage while allowing the protective layer to serve as a sacrificial element.
4Object-affected harmful factors
If insulating protective layer is added to protect cable, then protection against friction damage is improved, but electromagnetic interference increases
Solution Approach 1:
The patent introduces an insulating protective layer as an intermediary between the aluminum alloy skeleton and the external environment. This layer provides mechanical protection while the patent simultaneously adds shielding structures to mediate the electromagnetic interference issue.
Solution Approach 2:
The patent creates a composite structure combining insulating protective layer with electromagnetic shielding materials, achieving both mechanical protection and EMI shielding in a integrated design.
Data Source
AI summary
The present disclosure discloses a multi-core electric connector assembly, including at least two electric connection skeletons and connectors arranged at two ends of the electric connection skeleton, and the connectors includes an outer shell and a connection terminal, the connection terminal is arranged on the connector by means of a fixing member, at least one end of the electric connection skeleton is connected to the connection terminal, and insulating protective layers are arranged between the electric connection skeletons and on periphery of the electric connection skeletons. And a vehicle is included.