Phase-Shifted Shielded Connector for High Current
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Solution Overview
Problem
High electromagnetic interference in electrical connections between inverters and drive motors in modern motor vehicles leads to significant power loss and heating in plug connections due to interference currents, necessitating a reduction in current intensity to prevent overheating.
Innovation Solution
An electrical connection structure with phase-shifted electrical lines and distinct shields that are electrically conductively connected within the connector, allowing interference currents to be routed back to the source, thereby minimizing power loss and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high currents are transmitted through electrical lines with large cross-sections, then the power transmission capability is improved, but electromagnetic interference and heat generation in the connector increase
Solution Approach 1:
The patent converts the harmful electromagnetic interference and interference currents into a beneficial configuration by establishing a phase-shifted relationship between the first and second electrical lines. The interference currents generated in the shields are routed through the phase-shifted lines, transforming the harmful effect into a controlled current path that reduces heat generation in the connector while maintaining high power transmission capability.
2Object-affected harmful factors
If the first and second electrical lines are configured with phase shift, then electromagnetic interference coupling between shields is improved, but the device complexity increases
Solution Approach 1:
The patent merges the shielding functions of the first and second electrical lines by electrically conductively connecting their shields within the connector housing. This integration allows the shields to work together as a unified electromagnetic interference management system, improving coupling effectiveness while avoiding the complexity of separate, independent shielding configurations.
Solution Approach 2:
The patent establishes equipotential connections between the shields of the first and second electrical lines through electrical conductive connections within the connector housing. This creates balanced potential relationships that enhance electromagnetic interference coupling and reduce voltage differences that would otherwise contribute to heat generation and interference.
3Object-affected harmful factors
If interference currents are routed through the connector housing to ground, then electromagnetic shielding is improved, but power loss and heat generation increase
Solution Approach 1:
The patent introduces phase-shifted electrical lines as an intermediary path for interference currents. Instead of directly routing interference currents through the connector housing to ground (which causes power loss), the phase-shifted lines serve as a mediator that redirects these currents through a controlled path, reducing the burden on the connector housing and minimizing power loss while maintaining shielding effectiveness.
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
Significantly reduces power loss and heat in the plug connection, enabling higher current transmission or operation at higher ambient temperatures without overheating.
Implementation Method 1
electromagnetic interference is induced in the electrical conductor by the inverter, also known as the inverter. On the other hand, the electrical conductor itself generates electromagnetic interference due to magnetic induction
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electrical connecting structure (2) comprising an electrical plug connector (4) which has an insulating plug housing (15) and can be conductively connected to a mating electrical plug connector (6) that is rigidly connected to an electrical unit (16), in order to transmit high currents. The connecting structure (2) comprises a first (8) and a second (10) electrical line configured to transmit a first and a second current that have a first and a second phase position, the second phase position being temporally shifted relative to the first. The first (8) and second (10) lines comprise an associated first (12) and second (14) shield against electromagnetic interferences, and these first (12) and second (14) shields can be detachably and conductively connected to an associated third (20) and fourth (22) shield (20) located in the mating plug connector (6). According to the invention, the first (12) and second (14) shields differ from one another and are interconnected in a conductive manner within said electrical connecting structure (2).