Shielded EV Charging Connector Assembly for EMI Grounding
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Solution Overview
Problem
Traditional high-voltage connection mechanisms in electric vehicle charging systems have complex structures, high costs, and lack effective electromagnetic interference shielding, posing safety risks and assembly challenges.
Innovation Solution
A connection mechanism with an integrally injection-molded inner shell and plug-in terminal, featuring a protective shielding shell connected to a functional cable's shielding layer and grounding terminal, which includes a conductive elastic sheet for stable electrical connection and reduced interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal cover is used for shielding, then electromagnetic interference is reduced, but processing difficulty and cost increase
Solution Approach 1:
The patent replaces expensive metal covers with a cost-effective shielding net made of conductive mesh material. This shielding net achieves the same electromagnetic interference reduction function while being significantly cheaper and easier to process, aligning with the principle of using economical alternatives that maintain functional performance.
Solution Approach 2:
The patent employs a flexible shielding net that can be conformally mounted within the connection mechanism housing. This thin-film-like shielding structure is easier to process and install compared to rigid metal covers, reducing manufacturing complexity while maintaining shielding effectiveness across different surfaces and angles.
2Object-affected harmful factors
If a metal cover is used for shielding, then electromagnetic interference is reduced, but assembly time increases
Solution Approach 1:
The patent integrates the shielding net directly into the connection mechanism assembly process, combining multiple functions into a single component installation. The shielding net is designed to be mounted simultaneously with other internal components, eliminating separate assembly steps required for traditional metal covers and reducing overall assembly time.
3Object-affected harmful factors
If a metal cover is placed inside the connection mechanism, then shielding is achieved, but short-circuit risk increases
Solution Approach 1:
The patent uses a flexible shielding net with mesh structure that maintains electrical isolation between conductive components. The mesh design allows the shielding net to conform to internal surfaces without creating rigid contact points that could cause short circuits, while still providing effective electromagnetic shielding through its conductive properties.
Solution Approach 2:
The shielding net acts as an intermediary layer between conductive components within the connection mechanism. It provides electromagnetic shielding while its mesh structure and flexible nature prevent direct electrical contact between conductive parts, thereby eliminating short-circuit risks associated with solid metal covers.
4Adaptability or versatility
If traditional assembled structures are used, then flexibility is maintained, but structure complexity and cost increase
Solution Approach 1:
The patent integrates multiple components including the shielding net, mounting brackets, and structural supports into a unified assembly design. This consolidation reduces the number of separate parts and assembly operations required, simplifying the overall structure while maintaining the flexibility needed for different installation configurations and applications.
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 design simplifies processing, reduces costs, effectively shields electromagnetic interference, ensures double grounding, and monitors terminal temperature, enhancing safety and reducing assembly time.
Implementation Method 1
the protective shielding shell is at least partially electrically connected to the shielding layer... effectively shield electromagnetic interference in the connection mechanism
Implementation Method 2
one end of the protective shielding shell is at least partially electrically connected to the shielding layer, and the other end thereof is at least partially electrically connected to the protective conductor or the grounding terminal
Data Source
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AI summary
The present disclosure provides a connection mechanism having a shield, an electric energy transmission apparatus and a motor vehicle, in which the connection mechanism includes a functional cable, a plug-in terminal, a protective conductor, a grounding terminal, an inner shell integrally formed with the functional cable and the plug-in terminal, and a protective shielding shell disposed on at least part of an outer periphery of the inner shell; the functional cable is provided having a shielding layer, one end of the protective shielding shell is at least partially electrically connected to the shielding layer, and the other end thereof is at least partially electrically connected to the protective conductor or the grounding terminal; the connection mechanism having a shield is provided with the inner shell which is integrally injection-molded with the functional cable and the plug-in terminal, so that the processing is simple, and the cost is much lower than that of a shielding metal shell; through a plug-in cooperation between the connection mechanism having a shield and a mating connection mechanism, as well as the electrical connection having a shielding net of the functional cable and the shielding layer, it is possible to effectively shield the electromagnetic interference in the connection mechanism, and reduce the electromagnetic interference on other devices.