Shield Termination Housing for High-Temperature Cables
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Solution Overview
Problem
Existing electrical cables with shields require complex sealing methods that are limited to specific temperature ranges and are not suitable for harsh environmental conditions, particularly in high-voltage applications like electric vehicles, where reliability and durability are essential.
Innovation Solution
An electrical line design featuring a tightly sealing housing around the contact point between the shield and a shield lead-out conductor, with profiled seals and a crimp sleeve for enhanced protection and easy assembly, allowing for use in higher temperature ranges and harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a potting compound is used to seal the connection area in a connector housing, then the connection is sealed, but the sealing process becomes complex and is limited to temperature ranges of up to 90-100 °C
Solution Approach 1:
The patent extracts the sealing function from the complex potting compound process and implements it through separate seal elements (first seal and second seal) that can be independently installed and replaced. This simplifies the sealing process while maintaining reliability and enables use in higher temperature ranges.
Solution Approach 2:
The sealing system is segmented into multiple independent seal elements rather than using a single monolithic potting compound. The first seal seals the housing interior, while the second seal seals the connection area, allowing each seal to be optimized for specific functions and temperature ranges.
2Reliability
If traditional sealing methods are used, then the connection is protected, but the cable cannot be used in temperature ranges above 90-100 °C or in harsh environmental conditions
Solution Approach 1:
The patent changes the material parameters of the seal elements to enable operation in higher temperature ranges (up to 180 °C). The seal material is specifically selected to maintain its sealing properties at elevated temperatures and in harsh environmental conditions, thereby expanding the operational adaptability of the cable assembly.
3Ease of manufacture
If the shield connection is exposed to environmental influences, then the manufacturing process is simpler, but the connection becomes susceptible to corrosion and mechanical damage
Solution Approach 1:
The patent applies preliminary protective action by installing the first and second seals before the cable is put into service. This preliminary sealing protects the shield connection from environmental influences such as corrosion and mechanical damage throughout the cable's operational life, while maintaining manufacturing simplicity through modular assembly.
Data Source
Figure 1A~1C
Figure 2A~3C
Figure 4A~4B
AI summary
An electrical cable (100) with an insulated conductor (106, 107) surrounded by an electrical shield (109) is proposed. The electrical shield is contacted at a contact point (V) with an additional conductor (108), which forms a shield termination. A tightly sealing housing is mounted on the electrical cable around the shield termination and, in particular, the contact point (V), to protect the contact point (V) from environmental influences. The proposed electrical cable with shield termination is suitable for high-temperature applications up to 180 °C.