Shielded Cable Housing Segmentation for EMC
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Solution Overview
Problem
Existing shielded electric cable arrangements in vehicles face challenges in achieving continuous shielding between cables or conductors, particularly due to complex manufacturing and installation processes such as press-fitting contact sleeves, which complicate the production and installation of effective electromagnetic compatibility (EMC) solutions.
Innovation Solution
A cable arrangement featuring a rigid flat conductor bar with a continuous shield, connected to electric cables through a shield housing made of aluminum or aluminum alloy, where the cables are clamped within a two-part housing structure, eliminating the need for press-fitting and ensuring direct or indirect contact between shields for enhanced EMC, using overlapping housing lands and a ferrule system for secure clamping and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact sleeve is press-fitted into the opening of the shield housing, then good shielding for the cable arrangement is achieved, but the manufacturing process becomes complicated
Solution Approach 1:
The shield housing is divided into two separate parts (first housing part and second housing part) that are joined together. The opening is distributed across both parts, eliminating the need for a separate contact sleeve. This segmentation simplifies manufacturing by removing the press-fitting step while maintaining shielding effectiveness through the continuous shield connection between the two housing parts.
2Reliability
If a rigid flat conductor bar is used as ground wire in closely spaced relationship to electric cables, then electromagnetic compatibility is improved, but continuous shielding between multiple cables becomes complex to implement
Solution Approach 1:
The shield housing combines multiple functions into a single structure: it provides the ground connection via the flat conductor bar, maintains electromagnetic shielding, and ensures continuous shield connection between multiple cables. The two-part housing design with integrated shield transition elements merges these functions while simplifying the overall implementation of continuous shielding across multiple cables.
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
This solution simplifies the production and installation of continuous shielding, improves electromagnetic compatibility by ensuring tight clamping and electrical conductivity, and maintains effective shielding across various frequencies, including higher ones, while reducing the complexity of shield transitions.
Implementation Method 1
a shielded electric cable arrangement (1) for a vehicle (200)... improve the electromagnetic compatibility (EMC)... shield housing made of an aluminum material... ensuring direct or indirect contact between shields for enhanced EMC
Data Source
AI summary
An electrical cable arrangement comprises a dimensionally stable flat conductor bar with a flat conductor shield; at least one electric cable connected thereto and having a cable shield; and a shield housing made of an aluminum material and having a first housing part and a second housing part. Between the housing parts a closed accommodating chamber is formed for a connecting section between the flat conductor bar and the cable. When in the installed state, the flat conductor bar and the cable are each clamped tight between the housing parts by an end face section in such a manner that the flat conductor shield and the cable shield are directly or indirectly interconnected for the shield transition.